NUMBER: 9 12–10 S.M. REF.: Listed in Table ENGINE: DD Platform DATE: September 2010 SUBJECT: INSTALLATION OF THE FUEL INJECTOR ADDITIONS, REVISIONS, OR UPDATES Publication Number Platform Section Title Change Page Number(s) DDC-SVC-MAN-0082 EPA07/10 DD Platform 23.5 Installation of the Fuel Injector An EGR Cooler cleaning procedure reference is added to the procedure when a leaking injector is found. Insert as stated NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle. INSTALLATION OF THE FUEL INJECTOR Install as follows: NOTE: Ensure excess fuel is removed from the top of the piston dome before fuel injector installation. 1. If the fuel system is contaminated: [a] Drain the fuel tanks and refill with clean fuel. [b] Clean the fuel water/separator and replace the fuel filters. 2. If the coolant system is contaminated with fuel, flush and reverse flush the system. 3. If the oil system is contaminated, change the engine oil and filters. NOTICE: The fuel injector tube bore should be cleaned and inspected for damage or leakage of coolant before installation of the fuel injector. 4. Check to make sure the fuel injector tube bore is thoroughly clean. 5. If new injectors are being used, write down the new fuel injector's calibration code and note the cylinder location where it will be installed. 6. Remove fuel injector nozzle tip protector. NOTICE: The copper washer must be installed with recess (1) facing fuel injector body. Incorrect installation can cause combustion gasses to enter the fuel system. 7. Install a new copper washer with recess facing UP (1) toward the fuel injector and the flat side of the washer facing DOWN (2). 8. Apply a thin coat of acid free grease or clean engine oil to the fuel injector seal rings and then use J-48837 (fuel injector O-ring installer) to install them in the fuel injector nut ring grooves. Make sure they are properly seated. 9. Install the fuel injector and clamp as an assembly into its respective fuel injector bore. Align the clamp over the bolt hole, install the new bolt into fuel injector clamp and snug until the fuel injector fully seats, then release the fuel injector bolt. DO NOT torque. NOTE: If the high pressure lines leak after installation, the lines need to be replaced. 10. Install high pressure line to the injectors and fuel rail. Finger tighten the cap nuts. 11. Torque the fuel injector hold-down bolt to 20 N·m (15 lb·ft) + 90 degrees. 12. Using J-48770, torque the high pressure lines to the fuel injector to 40 N·m (29 lb·ft). 13. Torque bolts securing fuel injector feed line seal (1) to 15 N·m (11 lb·ft). 14. Insert the 14–pin connector from the fuel injector harness into the hole in the cam frame and install electrical connections and Allen head hold-down bolts before torquing. 15. Install the spring clip onto the 14–pin connector. 16. Torque all of the fuel injector connections to 1.5 N·m (12lb·in.). 17. Torque all of the Allen head fuel injector harness hold-down bolts to 10 N·m (7 lb·ft). 18. Input the fuel injector calibration codes that were recorded earlier into DDDL using the service routine. 19. If injectors were replaced because of a tip failure or leak, the EGR cooler must be cleaned. [a] For DD13: refer to section . [b] For DD15: refer to section . 20. Install rocker cover. Refer to section . 21. Connect batteries. Verify repair. 22. If more than one fuel injector was changed, reset the leak detection threshold for the high pressure fuel system. Refer to section . ADDITIONAL SERVICE INFORMATION Additional service information is available in Power Service Literature. Detroit Diesel®, DDC®, Series 60® and the spinning arrows design are registered trademarks of Detroit Diesel Corporation. © Copyright 2010 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.
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