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WARNING
The fuel pump, high-pressure fuel lines, and fuel rail contain
very high-pressure fuel. Do not loosen any fittings while the
engine is running. Wait at least 10 minutes after shutting
down the engine before loosening any fittings in the high-
pressure fuel system to allow pressure to decrease to a lower
level.
CAUTION
Use caution when disconnecting or removing fuel lines,
replacing filters, and priming the fuel system, that fuel is not
spilled or drained into the bilge area. Do not drop or throw
filter elements into the bilge area. The fuel and fuel filters
must be discarded in accordance with local environmental
regulations.
CAUTION
Installation of the banjo flow adapter at any place other than
the fuel drain manifold can cause damage to high-pressure
fuel system components.
Return fuel is routed from the injectors, the fuel rail pressure
relief valve, and the fuel pump head through three different
drain lines.
Measurement of fuel injector leakage requires the use of a fuel
return hose, Part Number 3164618.
The tool is used to isolate the leakage from just the injectors,
so it can be measured with a graduated cylinder.
Drill and tap the open end of the banjo bolt for the installation
of a 5/16-24 set screw.
WARNING
Depending on the circumstance, diesel fuel is flammable.
When inspecting or performing service or repairs on the fuel
system, to reduce the possibility of fire and resulting severe
personal injury, death, or property damage, never smoke or
allow sparks or flames (such as pilot lights, electrical
switches, or welding equipment) in the work area.
CAUTION
Use caution when disconnecting or removing fuel lines,
replacing filters and priming the fuel system that fuel is not
spilled or drained into the bilge area. Do not drop or throw
filter elements into the bilge area. The fuel and fuel filters
must be discarded in accordance with local environmental
regulations.
Remove the M12 banjo bolt that connects the fuel injector
drain line to the fuel drain manifold.
Install the M12 fuel return hose, Part Number 3164618, at the
fuel drain manifold.
Route the fuel return hose into a collection device.
Obtain a graduated cylinder that is marked in cubic
centimeters; example: graduated beaker, Part Number
3823705, or equivalent. A kitchen style measurement cup that
is marked in cubic centimeters (cc's) also works well.
Start the engine and allow the engine to idle until drain fuel
from the injector drain line begins to flow into the collection
container.
Connect INSITE™ electronic service tool.
If the engine will not start, these procedures are still valid;
however, the pass/fail specification is different.
If the engine will not start, drain flow must be measured while
engaging the starter for 30 seconds at a time.
CAUTION
Fuel is at high pressure during this test. After connecting the
test fitting, close the engine cover and stand clear of high-
pressure fuel lines.
If the engine will start, the following steps will determine if the
injector drain flow is excessive.
While the engine is operating at idle, use INSITE™ electronic
service tool High-Pressure Leak Test to create high fuel rail
pressure. INSITE™ electronic service tool will command 1500
BAR [21,756 psi] fuel rail pressure while the engine is at idle
during this test.
Record the amount of time it takes for 300 cc [10.1 oz] of fuel
to flow from the injector drain line when performing INSITE™
electronic service tool High-Pressure Leak Test.
CAUTION
Make certain the keyswitch is in the OFF position (engine not
operating) when loosening or tightening high-pressure fuel
lines.
Record the amount of time it takes for 300 cc [10.1 oz] of fuel
to flow from the injector drain line while the engine is
operating. Use INSITE™ electronic service tool High-Pressure
Leak Test. Do this up to six (6) times, once while each line is
isolated.
If isolating a single injector and high-pressure fuel connector
causes the leakage time to increase significantly compared to
the rest of the set, that injector and fuel connector must be
inspected.
Inspect the suspect fuel connector. Refer to Procedure 006-
052 in Section 6. (/qs3/pubsys2/xml/en/procedures/45/45-
006-052-tr.html)If the fuel connector is not damaged, replace
both the injector and the fuel connector.
Remove the M12 diagnostic flow adapter from the fuel drain
manifold and install the M12 banjo. Refer to Procedure 006-
013 in Section 6. (/qs3/pubsys2/xml/en/procedures/45/45-
006-013-tr.html)
Install all high-pressure fuel lines. Refer to Procedure 006-051
in Section 6. (/qs3/pubsys2/xml/en/procedures/45/45-006-
051-tr.html)
Operate the engine and check for leaks.
Preparatory Steps
CAPS Fuel System
CAUTION
Attempting to remove the injector without first removing the
fuel connector will cause damage to the injector body and/or
fuel connector.
CAUTION
Attempting to remove the injector without first removing the
fuel connector will cause damage to the injector body and/or
fuel connector.
Remove
CAPS Fuel System
Remove the injector hold-down clamp capscrew that is nearest
the exhaust manifold side of the engine.
Remove the injector hold-down clamp.
Remove the high-pressure fuel connector. Refer to Procedure
006-051 in Section 6.
(/qs3/pubsys2/xml/en/procedures/45/45-006-051-tr.html)
Test
Mechanical Injectors
WARNING
While testing the injectors, keep hands and body parts away
from the injector nozzle. Fuel coming from the injector is
under extreme pressure and can cause serious injury by
penetrating the skin.
Install the injectors on an injector test stand. Open the bypass
valve for the pressure gauge, so the spray pattern can be
checked.
Use the injector test fixture, Part Number 3162269, with the
injector nozzle test, Part Number 3376946.
Operate the test stand lever quickly several times to check the
spray pattern of the injectors. Verify that the correct number of
plumes are present for the number of holes in the injector. Also
pay close attention to the size and shape of each plume. If
possible, compare the spray pattern to that of a new injector
with the same assembly number.
Note : The injector spray pattern is an excellent
indicator of the nozzle hole condition. Check each
plume carefully. It is possible that only a single hole
has been damaged, resulting in degraded engine
performance.
Close the bypass valve for the pressure gauge and operate the
test stand lever to check the nozzle opening pressure. There
must be a good crisp "pop" when the nozzle opens and the
pressure must be within the specification for the assembly
number.
The injector will pop between 275 bar [3,989 psi] and 300 bar
[4,351 psi].
Disassemble
Mechanical Injectors
Place the injector in the injector clamp and remove the nozzle
retaining nut.
Note : Injectors covered under warranty by the
manufacturer must not be repaired. See the
manufacturer's warranty instructions.
Remove the nozzle, intermediate plate, spring, and shims from
the injector.
WARNING
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.
CAUTION
Do not use any abrasives (such as glass beading, sand paper,
emery cloth, Scotch-Brite™ pads, etc) or metallic items
(including wire brushes made of any metallic material) to
clean the injectors. The use of any cleaning method other
than safety solvent and a soft, clean, lint-free cloth will
damage the nozzle holes and cause performance issues.
Clean the injector tip and body with safety solvent and a soft,
clean cloth.
Assemble
Mechanical Injectors
Clean the injector internal components with clean diesel fuel
and a clean cloth. Make sure there is no debris in the internal
parts of the injector.
Install
CAPS Fuel System
CAUTION
Do not overtighten the injector harness. The injector
terminals will be damaged if excessively over-tightened.
Finishing Steps
CAPS Fuel System
Install the fuel connector. Refer to Procedure 006-052 in
Section 6. (/qs3/pubsys2/xml/en/procedures/45/45-006-
052-tr.html)
Install the rocker lever cover. Refer to Procedure 003-011
in Section 3. (/qs3/pubsys2/xml/en/procedures/45/45-
003-011-tr.html)
Install the high-pressure fuel lines. Refer to Procedure 006-
051 in Section 6.
(/qs3/pubsys2/xml/en/procedures/45/45-006-051-
tr.html)
Operate the engine and check for leaks.
Last Modified: 27-Sep-2017