Inyectores

Service Training
MALAGA

ELECT. ENG. CONTROL

HEUI - LAB
- TOOLS NEEDED
- INJECTOR INSTALLATION
- SPEED/TIMING SENSOR INSTALLATION
-TIMING CALIBRATION
- INJECTOR ACTUATION PRESSURE TEST
- HYDRAULIC PUMP TEST
- INJECTOR TESTING

THORBEN
MARCH 1998

ELECT. ENG. CONTROL
CHAPTER : HEUI

TOOL NEEDED
JERD2124 - CAT ELECTRONIC TECHNICIAN SINGLE USE
LICENSE
JERD2129 - CATELECTRONIC TECHNICIAN ANNUAL DATA
SUBSCRIPTION (ALL ENGINE AND MACHINES)
7X1700 - COMMUNICATION ADAPTER
7X1688 - CONNECTOR CABLE
7X1412 OR 139-4166 - DATA LINK CABLE
DIGITAL MULTIMETER
7X1710 - CABLE PROBES
131-3921 - HYDRAULIC UNIT INJECTOR PULLER
111-5051 - HYDRAULIC UNIT INJECTOR SLEEVE REMOVAL WRENCH

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ALLEN SCREWS
HORIZONTAL BOLTS
INJECTOR CLAMP

JUMPER TUBEINJECTOR OIL
ADAPTOR

VERTICAL BOLTS

CHAPTER : HEUI

INJECTOR INSTALLATION

CHAPTER : HEUI

INJECTOR INSTALLATION
The correct procedures for injector removal and installation must be followed to avoid strain on the
injector and hydraulic leaks in the jumper tube area. The three mating surfaces of the jumper tube, oil
adaptor and injector must be aligned before final torque isapplied.

Injector assembly and installation
This portion of the assembly procedure ensures that all mating and sealing faces are flush and in
complete contact before tightening the bolts.
1. Clean the faces of the injector and the injector sleeve and install new o-rings.
2. Lubricate the o-rings with oil and insert the injector in the injector sleeve.
3. Visually align the injector with the flatsurface parallel to the centerline of the engine.
4. Position the injector clamp on the injector and tighten the bolt to
47 ± 9 N•m (35 ± 7 lb. ft.).
5. Install new seals on the jumper tube and rocker arm base.
6. Place the injector oil adaptor and jumper tube in position.
7. Install the allen screws and hex head bolts finger tight. If the injector oil adaptor was previously
installed onthe injector, loosen the allen screws.

The objective at this point in the procedure is to bring all the mating faces into complete contact and
alignment before starting the final torque procedure.
Failure to align the components will put a strain on the injector which will then distort the poppet valve
and barrel bores. These components operate with a clearance of 5 microns because of the highinjection
and hydraulic pressures. Therefore, even a small amount of distortion will cause a seizure.
Additionally, some misalignment could cause combustion gases to enter the supply system.

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CHAPTER : HEUI

INJECTOR INSTALLATION

Injector installation torque sequence
After all the mating surfaces are aligned, the torquing procedure can be performed:
1. Tighten the allenscrews and hex head bolts finger tight or just sufficiently to bring the mating
surfaces together and into alignment.
2. Apply an initial torque to the vertical hex head bolts of 5 ± 3 N•m (4 ± 2 lb. ft.).
3. Apply an initial torque to the horizontal hex head bolts of
5 ± 3 N•m (4 ± 2 lb. ft.).
4. Apply an initial torque to the allen screws of 1 ± 0.2 N•m
(10 ± 2 lb. in.).
5. Final torquethe vertical hex head bolts to 47 ± 9 N•m
(35 ± 7 lb. ft.).
6. Final torque the horizontal hex head bolts to 47 ± 9 N•m
(35 ± 7 lb. ft.).
7. Final torque the allen screws to 12 ± 3 N•m (9 ± 2 lb. ft.).
8. Check the system for leaks (crank with injection disabled). Then, check the hydraulic pressure
(compare with desired pressure).

A number of possibilities for leaks can exist. Oil underhigh pressure may leak from the jumper tube
joints or from the injector valve body exhaust port. Fuel could leak from the upper seal on the injector.
Also, combustion gas can possibly leak from the base of the injector.
If air has entered the fuel supply system, multiple injectors on one bank may malfunction. If the above
procedure was not followed, air could enter past the lower o-ring seal....