FUEL INJECTOR REPAIR (Contd)
Be certain all mating surface parts are clean and free of burrs or defects which will result in
incorrect flow or torque.
Check ball (12)
Insert in barrel (9).
Two roll pins (13)
Install on top-stop adapter (7).
Be aware that check ball could fall out during assembly of barrel and injector cup which
could render injector useless.
Barrel (9) and injector cup
Insert in top-stop adapter (7).
Apply a light coat of OE/HDO 10
lubricating oil to barrel (9) and
injector cup (10).
Cup retainer (11) and top-
Screw down finger-tight. Loosen
stop adapter (7)
Do not perform fuel system procedures while smoking or within 50 ft (15.2 m) of sparks or
open flame. Diesel fuel is flammable and may explode. Failure to comply may result in
injury to personnel.
Insert in injector assembly (1).
Immerse plunger (2) in clean
Injector assembly (1)
Place in injector stand (17)
a. Position base with single pin
in center of injector stand (17).
b. Back off stud (22) from injector
Lubricate threads on stud (22)
stand (17) and slide clamp bar (21)
and screw in injector stand (17)
over injector assembly flats (20).
with OE/HDO 10 lubricating oil.
c. Place retainer cup wrench (19)
on cup retainer (11).
d. Tighten stud (22) in injector
This aligns cup and injector
stand (17) to 75 lb-in. (8. Nm).
When removing injector from injector stand, do not hit cup retainer on stud.
e. Tighten cup retainer (11) with
Use crowfoot wrench (ST-1072).
crowfoot wrench to 53-57 lb-ft
Remove from injector stand
(ST-1298) (17) when task is com-
Check injector cup (10) to plunger
(2) alignment as follows:
a. Coat plunger (2) with clean
Hold injector assembly (1) with
injector cup (10) down and allow
plunger (2) to drip a few drops of
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