| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 5F-4764 | Pry Bar | 1 |
| B | 6V-4062 | Spring Compressor | 1 |
Start By:
- Remove the rocker shaft assembly and the pushrods.
| NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
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Personal injury or death can result from the engine starting. The engine can start and injure persons working on or near the engine. Be sure the engine cannot be started while service work is being performed. This is very important when the engine is equipped with an Automatic Start Stop System. On engines equipped with an air starting system, close the air supply valve to the air starting motor before service work is begun. |
- Turn OFF the fuel supply to the engine.
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Illustration 1 g02027452 - Remove tube assembly (1) and tube assembly (2). Cap the fuel openings.
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Illustration 2 g02027513 - Remove locknut (8). Disconnect lever assembly (5) from control rod (7).
- Remove bolts (6) and lever assembly (5).
- Remove the bolt and clamp (3).
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NOTICE Do not pry the unit injector with a heel bar because damage (bending) to the fuel rack can occur. This will make unit injector replacement necessary.
- Use Tooling (A) to loosen fuel injector (4). Remove fuel injector (4).
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Illustration 3 g02028135 - Remove O-ring seals (9) from fuel injector (4).
- Install a plastic plug in the fuel injector opening in the cylinder head.
Note: Put a clean cover over the cylinder head in order to prevent the entry of airborne dust or abrasive particles into the engine.
- Install fuel injector (4) in the reverse order of removal.
- Use Tooling (B) to ensure that the fuel injection rack moves freely.
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NOTICE Remove all carbon deposits from the angled surface at the bottom of the cylinder head bore for the fuel injection pump. Failure to clean this area may prevent the fuel injection pump from seating properly. This could result in failure of the fuel injection pump due to leakage of exhaust gas into the fuel passage.
- Ensure that the cylinder head bore and the fuel injector are thoroughly clean and that no carbon deposits remain.
- Apply clean engine oil to the O-ring seals.
- Tighten the bolt for clamp (3) to a torque of
65 ± 7 N·m (48 ± 5 lb ft) . - Check the fuel injection timing. Refer to Testing and Adjusting, "Fuel Injection Synchronization".
- Use Tooling (B) to ensure that the fuel injection rack moves freely.