TM 9-2815-202-34
4-40. FUEL INJECTOR ASSEMBLY
This task covers:
a. Disassembly
d. Lapping
INITIAL SETUP
MODELS
TOOLS AND SPECIAL TOOLS
General mechanics tooI kit (App B, Item 96)
Injector holding fixture (App B, Item 20)
Spray tip remover (App B, Item 95)
Rack hole cleaning brush (App B, Hem 95)
Pin vise (App B, Item 95)
Spray tip wire (App B, Item 95)
Fuel hole cleaning brush (App B, Item 95)
Injector body reamer (App B, Item 95)
Nut reamer (App B, Item 95)
Nut reamer - tip hole (App B, Item 95)
Spring tester (App B, Item 93)
REPAIR
b. Cleaning
c.
e. Assembly
f.
Inspection/Measurements
Testing
Wire rotary brush (App B, Item 9)
Spray tip carbon remover (App B, Item 95)
Diesel fuel tester (App B, Item 91)
Micrometer (1-2”) (App B, Item 65)
Micrometer (0-1”) (App B, Item 65)
MANDATORY REPLACEMENT PARTS
1 Seal ring (App F, Item 141)
2 Gaskets (App F, Item 77)
.
1 Filter (App F, Item 14)
EXPENDABLE/DURABLE SUPPLIES
Fuel oil (App C, Item 21)
Cleaning solvent (App C, Item 10)
Lapping compound (App C, Item 25)
Engine oil (App C, Item 16)
Needle valve height gage (App B, Item 35)
Torque wrench (App B, Item 101)
Lapping blocks (App B, Item 7)
EQUIPMENT CONDITION
Diesel test fixture (App B, Item 89)
Injector nut socket (App B, Item 95)
Para Description
Injector tip concentricity gage and
4-38 Injectors removed (7083-7395 and
rack freeness tester (App B, Item 92)
7083-7398)
5-37 Injectors removed (7083-7391,
7083-7396 and 7083-7399)
a. Disassembly
(1) Place injector upright in injector holding fixture
(2) Remove two shipping caps (2), two
fuel line connectors (3), two gaskets
(4), and fuel filter (5) from injector.
Discard filter and gaskets.
(3) Rotate spring until spring end is clear
of pin (6). Compress follower spring
(7) by pressing down on follower (8).
Then raise follower spring above stop
pin (6) with a screwdriver and
withdraw stop pin. Allow spring to rise
gradually by releasing pressure on
follower.
(4) Remove follower (8), follower spring
(7), and plunger (9) from injector as
an assembly.
4-222
Change 1
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