Usage:
Before removing or disconnecting a fuel line, clean the cylinder head area around the fuel line connection.
INJECTION NOZZLE (Right side illustrated)
1. Lines (eight, four each side). 2. Injection nozzles (eight, four each side). 3. Clamps (eight, four each side).
1. Remove valve cover, fuel return manifold, and rocker arm assembly.
2. Remove the fuel injection nozzle clamp (3).
3. Disconnect the fuel injection nozzle (2) and the fuel injection line (1) from the adapter.
4. Remove the adapter (4) and lift injection nozzle (2) out of the cylinder head.
ADAPTER AND NOZZLE REMOVAL
2. Injection nozzle. 4. Adapter. 5. O-ring seal. 6. O-ring seal.
| NOTICE |
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Pull nozzle straight out, by hand, to remove. Slight twisting action is permissible if necessary. Never pry out a nozzle with a screwdriver or other similar tool. |
NOTE: Always replace O-ring seals (5) and (6) before installing nozzle.
5. Use needle-nose pliers to remove carbon seal dam (8). Always install a new compression seal (7) and carbon seal dam (8) before installing injection nozzle.
REMOVING CARBON SEAL DAM
7. Compression seal. 8. Carbon seal dam.
Install Fuel Injection Nozzles
1. Be sure the bore in the cylinder head and fuel inlet fittings are clean.
| NOTICE |
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Never install an injection nozzle that has been dropped, without first testing it with the 8S2242 Nozzle Tester Group. The injector tips are very hard and brittle and break easily. |
2. Install a new compression seal and carbon seal dam. Use an 8S2252 Carbon Seal Dam Installation Tool (9) to install the carbon seal dam.
INSTALLING CARBON SEAL DAM
9. 8S2252 Carbon Seal Dam Installation Tool.
3. Install a new O-ring seal (6) on the injection nozzle (2) and a new O-ring seal (5) on the adapter (4).
4. Install the injection nozzle (2) into the cylinder head using a twisting motion. Do not use lubricant in the cylinder head bore or on the nozzle body.
INSTALLING NOZZLE
2. Injection nozzle. 4. Adapter. 5. O-ring seal. 6. O-ring seal.
| NOTICE |
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Do not bend the injector inlet connection when installing injector into cylinder head. Bending of the inlet connection creates tension on the injector and causes binding of the needle in the guide. |
5. Install the adapter (4) and tighten the injection nozzle-to-adapter retaining nut. Tighten retaining nut to 30 ± 5 lb. ft. (4.1 ± 0.7 mkg). Hand tighten the fuel injection line.
6. Install the injection nozzle clamp.
7. Install the fuel return manifold and rocker arm assembly. Install retaining bolts and locks. Tighten bolts to 18 ± 5 lb. ft. (2.5 ± 0.7 mkg) and bend locks.
8. Adjust the intake valve clearance to .015 in. (0.38 mm) and the exhaust valve clearance to .025 in. (0.64 mm).
9. Install valve cover. Install mounting bolts and tighten to 120 ± 24 lb. in. (138 ± 28 cm.kg).
10. Purge the fuel lines of air by motoring the engine until fuel, free of air, flows from the connections.
11. Tighten the fuel line connections to 30 ± 5 lb. ft. (4.1 ± 0.7 mkg).
12. Start the engine and correct any fuel leaks that may occur.
Disassemble Fuel Injection Nozzle (9L9263 Nozzles)
Do not disassemble the nozzle unless testing indicates that servicing is necessary. See the TESTING AND ADJUSTING section of the Service Manual.
NOTE: Do not clean or readjust a nozzle that has excessive return leakage. Excessive return leakage is a sign of impending major nozzle failure that cannot be corrected by cleaning or adjusting and can possibly result in serious engine damage.
| NOTICE |
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Use extreme care in keeping the work area and tools clean. Handle all parts with care to avoid any damage. |
1. Place the nozzle in the holding tool (2) and secure the tool in a vise. Do not clamp any part of the nozzle body directly in the vise.
2. Loosen pressure adjusting screw locknut (1).
3. Holding the nozzle in one hand, invert it and back out the pressure adjusting screw allowing the spring, spring seats and ball washer to fall into your hand. The valve may slide out, by its own weight, and should be handled carefully by its stem.
REMOVING LOCKNUT (Typical Example)
1. Locknut. 2. 8S2250 Nozzle Holding Tool.
LOCKNUT REMOVED (Typical Example)
4. If the valve does not fall out, remove it with retractor (3). To prevent bending the valve, bottom it in the body with the retractor. Push down on the retractor body to mount the collet. Turn the knurled nut counterclockwise to secure the collet and withdraw the valve.
REMOVING VALVE
3. 8S2254 Valve Retractor.
5. Place the parts in solvent to loosen carbon and deposits of foreign material. Do not soak the body assembly in solvent for over 1 to 2 hours. The solvent can damage the epoxy bond used to secure the body assembly components together.
Assemble Fuel Injection Nozzle (9L9263 Nozzles)
NOTE: Before assembly, wash all parts thoroughly. Flush the body to remove any debris or lapping compound. Assemble while all parts are wet with clean fuel.
1. Handle valve (1) by its shank and slide it partially into the body.
2. Assemble ball washer (5), spring upper seat (4), spring (3) and spring lower seat (2) to the lift and pressure adjusting screw assembly (6).
3. Tilt the nozzle body and with spring lower seat (2) in contact with the top of valve (1), as illustrated, push the valve and spring components into the body.
| NOTICE |
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Be careful not to dislodge spring lower seat (2) during assembly. |
ASSEMBLING NOZZLE (Typical Example)
1. Valve. 2. Spring lower seat. 3. Spring. 4. Spring upper seat. 5. Ball washer. 6. Lift and pressure adjusting screw assembly.
4. Tighten the adjusting screw assembly (6) by hand until the spring compresses with enough force to hold all the parts in place (8 to 10 turns).
5. Adjust valve lift, opening pressure and tighten the locknut. See covering topics.
Service And Inspect Fuel Injection Nozzle (9L9263 Nozzles)
1. Use the brush (4) to clean the tip and body exterior.
2. Secure the 8S2247 Cleaning Wire [.008 to .009 in. (0.20 to 0.23 mm) dia.] in pin vise (1) with 1/32 in. (0.79 mm) to 1/16 in. (1.59 mm) of wire protruding. A longer length of wire can bottom in the sac hole and break off in the orifice. Remove any burrs from the wire tip with the 8S2260 Stone. Stoning a flat surface on one side of the wire helps in reaming carbon from a clogged orifice.
Insert the wire into each orifice and rotate it slowly until it turns freely.
| NOTICE |
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Do not use a punching action to remove deposits from the orifices. |
Select the 8S2246 Wire [.011 in. (0.28 mm) maximum diameter] and repeat the cleaning procedure. Flush the body thoroughly and inspect the tip. If any orifices are chipped at the edges or eroded to an extent that the spray pattern can be affected, replace the nozzle.
CLEANING TIP
1. 8S2256 Pin Vise.
3. Use scraper (2) to remove any deposits from the seat area.
CLEANING SEAT (Typical Example)
2. 8S2255 Scraper.
4. Insert drill (3) into the nozzle body and rotate it to remove any accumulations from the sac hole area.
5. After cleaning the sac hole area, repeat the orifice cleaning procedure.
CLEANING SAC HOLE (Typical Example)
3. 8S2251 Drill.
6. Use brass wire brush (4) to remove deposits from the seating area on the tip of valve (5). Inspect the valve seat for any pitting or erosion which will cause leakage.
| NOTICE |
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Never use a steel wire brush on nozzle parts. |
CLEANING VALVE TIP
4. 8S2258 Brush. 5. Valve.
7. Use solvent and the 8S2249 Cleaning Pad to remove varnish deposits from the valve.
8. Inspect the guide area of the valve for scratches which might cause sticking. This area will generally be polished on one side during operation and visible vertical marks are normal.
Reconditioning Fuel Injection Nozzle (9L9263 Nozzles)
If cleaning does not restore the nozzle to its proper operating condition, the valve seat or guide can be reconditioned.
1. If the return leakage is low lap the guide as follows:
a. Place a small amount of 8S2259 Lapping Compound on the valve in the guide area.
b. Slide valve (2) into body (1).
c. Bottom the valve in the body and grasp it with valve retractor (3).
LAPPING GUIDE
1. Body. 2. Valve. 3. 8S2254 Valve Retractor.
d. Rotate the valve in the guide about ten revolutions while raising and lowering it slightly.
| NOTICE |
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Never use motor driven chucks for this operation. The amount of material removal required is normally only a few millionths of an inch. |
e. Flush thoroughly and wash the compound from the valve and nozzle before assembling.
f. If the return leakage is still low when checked, repeat the lapping procedure until the correct leakage is obtained.
2. To decrease tip leakage lap the valve to the tip seat as follows:
a. Place a small amount of 8S2259 Lapping Compound on the valve seat.
b. Slide the valve (2) into the body (1).
c. Bottom the valve in the body and grasp it with the valve retractor (3).
d. Rotate the valve by hand, first clockwise then counterclockwise for a total of 3 to 5 revolutions.
| NOTICE |
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Never attempt to use motor driven chucks for this purpose. Excessive lapping will destroy the interference angle between the seat and valve. |
e. Flush body thoroughly, wash the valve and reassemble.
f. Check seat condition on the tester. If seat condition is not satisfactory discard the nozzle.
Disassemble Fuel Injection Nozzle (9L7883 Nozzles)
Do not disassemble the nozzle unless testing indicates that servicing is necessary. See the TESTING AND ADJUSTING section of the Service Manual.
NOTE: Do not clean or readjust a nozzle that has excessive return leakage. Excessive return leakage can be a sign of impending major nozzle failure that cannot be corrected by cleaning or adjusting and can possibly result in serious engine damage.
| NOTICE |
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Use extreme care in keeping the work area and tools clean. Handle all parts with care to avoid any damage. |
1. Place the nozzle in the holding tool (2) and secure the tool in a vise. Do not clamp any part of the nozzle body directly in the vise.
LOOSENING LOCKNUT
1. Locknut. 2. 8S2250 Nozzle Holding Tool.
2. Loosen lift adjusting screw locknut (1). Loosen the lift adjusting screw two or three turns. Loosen pressure screw (3).
3. Holding the nozzle in one hand, invert it and back out the pressure screw allowing the spring, spring seat and shims to fall into your hand. The valve may slide out, by its own weight, and should be handled carefully by its stem.
LOOSENING PRESSURE SCREW
3. Pressure screw.
PRESSURE SCREW ASSEMBLY REMOVED
4. If the valve does not fall out, remove it with retractor (4). To prevent bending the valve, bottom it in the body with the retractor. Push down on the retractor body to mount the collet. Turn the knurled nut counterclockwise to secure the collet and withdraw the valve.
REMOVING VALVE
4. 5P958 Valve Retractor.
5. Place the parts in solvent to loosen carbon and deposits of foreign material. Do not soak the body assembly in solvent for over 1 to 2 hours. The solvent can damage the epoxy bond used to secure the body assembly components together.
Assemble Fuel Injection Nozzle (9L7883 Nozzles)
NOTE: Before assembly, wash all parts thoroughly. Flush the body to remove any debris or lapping compound. Assemble while all parts are wet with clean fuel.
1. Handle valve (1) by its shank and slide it partially into the body.
ASSEMBLING NOZZLE
1. Valve. 2. Spring seat. 3. Spring. 4. Shims. 5. Pressure screw. 6. Locknut. 7. Lift adjusting screw.
2. Assemble lift adjusting screw (7) into pressure screw (5) two to three turns and install locknut (6), do not tighten the locknut. Put shims (4), spring (3), and spring seat (2) on the lift adjusting screw. Put the thickest shim (4) against the screw.
3. Tilt the nozzle body and with spring seat (2) in contact with the top of valve (1), push the valve and spring components into the body and tighten the pressure screw hand tight.
4. Put the nozzle in the 8S2250 Nozzle Holding Tool. Put the holding tool in a vise and tighten the pressure screw (5) to 75 to 80 lb. in. (86.5 to 92.2 cm.kg).
TIGHTENING PRESSURE SCREW
NOTE: To check or adjust the opening pressure and the valve lift see the TESTING AND ADJUSTING section of the Service Manual.
5. To tighten the locknut, hold lift adjusting screw (7) with a screwdriver and tighten the locknut (6) just enough so lift adjusting screw (7) will not turn.
TIGHTENING LOCKNUT
6. Use a torque wrench and tighten the locknut to 35 to 40 lb. in. (40.4 to 46.1 cm.kg).
TIGHTENING LOCKNUT
Service And Inspect Fuel Injection Nozzle (9L7883 Nozzles)
1. Use the brush (4) to clean the tip and body exterior.
2. Secure the 8S2247 Cleaning Wire [.008 to .009 in. (0.20 to 0.23 mm) dia.] in pin vise (1) with 1/32 in. (0.79 mm) to 1/16 in. (1.59 mm) of wire protruding. A longer length of wire can bottom in the sac hole and break off in the orifice. Remove any burrs from the wire tip with the 8S2260 Stone. Stoning a flat surface on one side of the wire helps in reaming carbon from a clogged orifice.
Insert the wire into each orifice and rotate it slowly until it turns freely.
| NOTICE |
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Do not use a punching action to remove deposits from the orifices. |
CLEANING TIP
1. 8S2256 Pin Vise.
Select the 8S2246 Wire [.011 in. (0.28 mm) maximum diameter] and repeat the cleaning procedure. Flush the body thoroughly and inspect the tip. If any orifices are chipped at the edges or eroded to an extent that the spray pattern can be affected, replace the nozzle.
3. Use scraper (2) to remove any deposits from the seat area.
CLEANING SEAT (Typical Example)
2. 8S2255 Scraper.
4. Insert drill (3) into the nozzle body and rotate it to remove any accumulations from the sac hole area.
CLEANING SAC HOLE (Typical Example)
3. 8S2251 Drill.
5. After cleaning the sac hole area, repeat the orifice cleaning procedure.
6. Use brass wire brush (4) to remove deposits from the seating area on the tip of valve (5). Inspect the valve seat for any pitting or erosion which will cause leakage.
CLEANING VALVE TIP (Typical Example)
4. 8S2258 Brush. 5. Valve.
| NOTICE |
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Never use a steel wire brush on nozzle parts. |
7. Use solvent and the 8S2249 Cleaning Pad to remove varnish deposits from the valve.
8. Inspect the guide area of the valve for scratches which might cause sticking. This area will generally be polished on one side during operation and visible vertical marks are normal.
Reconditioning Fuel Injection Nozzle (9L7883 Nozzles)
If cleaning does not restore the nozzle to its proper operating condition, the valve seat or guide can be reconditioned.
1. If the return leakage is low lap the guide as follows:
a. Place a small amount of 8S2259 Lapping Compound on the valve in the guide area.
b. Slide valve (2) into body (1).
c. Bottom the valve in the body and grasp it with valve retractor (3).
d. Rotate the valve in the guide about ten revolutions while raising and lowering it slightly.
LAPPING GUIDE (Typical Example)
1. Body. 2. Valve. 3. 5P958 Valve Retractor.
| NOTICE |
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Never use motor driven chucks for this operation. The amount of material removal required is normally only a few millionths of an inch. |
e. Flush thoroughly and wash the compound from the valve and nozzle before assembling.
f. If the return leakage is still low when checked, repeat the lapping procedure until the correct leakage is obtained.
2. To decrease tip leakage lap the valve to the tip seat as follows:
a. Place a small amount of 8S2259 Lapping Compound on the valve seat.
b. Slide the valve (2) into the body (1).
c. Bottom the valve in the body and grasp it with the valve retractor (3).
d. Rotate the valve by hand, first clockwise then counterclockwise for a total of 3 to 5 revolutions.
| NOTICE |
|---|
Never attempt to use motor driven chucks for this purpose. Excessive lapping will destroy the interference angle between the seat and valve. |
e. Flush body thoroughly, wash the valve and reassemble.
f. Check seat condition on the tester. If seat condition is not satisfactory discard the nozzle.