Usage:
3600 Family Of Engines
Reference: Service Manual Modules, Form SENR3600, Disassembly And Assembly of 3606 And 3608 Diesel Engines, and Form SENR3594, Disassembly And Assembly of 3612 And 3616 Diesel Engines. See the section, "Install Unit Injector."
Incorrect installation of unit injectors in the cylinder head can cause interference between the unit injector spring and clamp. This could result in broken injector springs or clamp bolts. Use the procedure that follows to install unit injectors in 3600 Family Of Engines. Make a note of this new procedure in the referenced Service Manual Modules.
Install Unit Injector
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Remove the protective plug in the unit injector opening. Carefully insert a screwdriver with a long blade through the unit injector opening until it contacts the top of the piston. Withdraw the screwdriver, and check for fuel or engine oil on top of the piston. If fluids are present, use an oil sampling vacuum withdrawal pump to remove the accumulation. Excessive liquid accumulation of top of the piston can cause hydraulic lock and engine damage.
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1. Install new seals on unit injector (1). The serrated portion of the flat seal must not line up with the flat surface on the unit injector body or the coolant ports in the cylinder head.
2. Put clean engine oil on the seals.
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Do not let the tip of the unit injector contact any components. Damage to the tip will make it necessary to replace the unit injector.
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3. Carefully lower unit injector (1) into place in the cylinder head. Be sure dowels (2) on the unit injector are around the bridge dowel. Be sure the notch in fuel rack (3) engages with the round bolt in the fuel rack lever.
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Do not tap on the top of the unit injector to seat it in its bore. Damage to the tip can occur. This will make it necessary to replace the unit injector.
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NOTE: Be sure the top surface of the clamp is parallel to the top surface of the cylinder head within 2.00 mm (.079").
Install clamp (6), washers (5), and bolts (4). Tighten the bolts evenly to move the unit injector into position. Tighten the bolts evenly to a torque of 45 ± 7 N·m (33 ± 5 lb ft).
5. Measure the distance between the top surface of clamp (6) and the surface of the cylinder head next to each hold-down bolt (4), dimensions (X) and (Y). The measurements must be equal to within 2.00 mm (.079").
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If the clamp is not centered around the injector spring, contact between the spring and clamp can occur when the engine is running. This could result in broken injector springs or hold-down clamp bolts.
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6. Inspect the area between the side of the unit injector spring and the hold-down clamp. The clamp should be centered around the spring. The distance between the spring and the clamp, side to side, should be approximately the same and the distance between the spring and clamp, front to rear, should be approximately the same.
7. If the clamp is not centered around the spring, remove the bolts that hold the clamp in place. Rotate the clamp 180° and repeat Steps 4 through 6.
8. After the bolts have been tightened, unit injector rack (3) must move freely.
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The fuel rack and fuel control linkage must be synchronized. See the topic, Injector Synchronization in Testing and Adjusting, Form SENR3599 for 3606 and 3608 Engines and Form SENR3593 for 3612 and 3616 Engines.
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9. Remove the protective caps and install fuel supply tube (8) and fuel return tube (7).
10. Install the plug in the fuel pressure control valve.