properly. The delivery valve holder must be assembled with a twelve
point wrench, and retorqued to 70-80 ft-lbs dry. The cap nut must be
retroqued to 55-60 ft-lbs dry. On ASK equipped generators, refer to
Operator and Organizational Maintenance Manual and install right
panel and top panel assemblies.
7-19. CYLINDER BLOCK.
(1) Steam clean cylinder block to remove de-
posits of oil and dirt. Immerse block in solvent tank
to clean out internal passages.
(2) Inspect top surface of cylinder block, the
surface that mates with the cylinder head, for warping.
Check both across cylinders and in line with cylinder.
(3) Use magnetic particle method to check the
cylinder block for cracks. Replace block if cracked.
(4) Cylinder walls should be free of scratches,
pitting and scuffing. Check each cylinder with an
inside reading micrometer for out -of -round and wear.
See Table 1-2 for bore measurements.
b. Overhaul and Rebuild. Always de-glaze cylinder
walls. If necessary, hone or rebore the cylinder to
fit the next available oversize piston. Pistons and
rings are available in 0.005, 0.010, 0.020, 0.030 and
0.040 inch oversize. If cylinders do not need re-
finishing, remove any existing ridges from top of wall
with a fine stone.
c. Install. If the cylinder block requires replace-
ment a new set of injection pump shims must be used
and the injection pump must be re-timed. The shims
are supplied with the replacement cylinder block. Refer
to paragraph 7-18 a. (3) for calculation of shim
7-20. FUEL INJECTOR,
All injector openings and injector nozzles
must be capped when the injector is removed
from the engine.
a. Removal. On ASK equipped generators, refer to Operator and
Organizational Maintenance Manual and remove top panel
(1) Remove fuel lines (3 and 7, figure 7-1) at fuel
(2) Remove screws (1, figure 7-45), washers (2)
and retaining flanges (3).
(3) Remove fuel injector (4), gasket (5), adapter
(6), gasket (7), heat shield (8) and gasket (9). Separate
injector from other components.
Do not attempt to disassemble nozzles or
adjust nozzle pressure without the proper test
equipment. A nozzle pressure tester is essen-
tial to do this work.
Do not allow nozzle to spray against skin. Fuel
under nozzle pressure can penetrate flesh and
cause a serious infection.
b. Test. Install nozzle to be tested on a static fuel
nozzle testing fixture. Increase fuel pressure until
nozzle opens. Opening pressure should be 1950 ± 25
psi for a new nozzle or 1750 ± 25 psi for a used
nozzle (200 hours or more). If nozzle opening pres-
sure is lower, adjust to 1950 psi for a new nozzle or
1750 psi for a used nozzle (see adjustment procedure).
(1) Remove pipe plug (1, figure 7-46).
(2) Loosen (do not remove) cover (2).
(3) Install injector nozzle on a static fuel nozzle
(4) Insert a 5/32 inch hex socket key through hole
in cover (2).
(5) Adjust opening pressure with hex key to cor-
rect pressure (1750 Psi for a used injector, 1950 psi
for a new injector). -
(6) Tighten cover
(2), and recheck opening pres-
When removing and disassembling fuel in-
jectors, separate and label components of each
injector. Never interchange components of in-
Never clamp injector in a vise without soft
(1) Secure injector in a holding fixture and re-
move nozzle cap nut (12, figure 7-46) and nozzle (9).
Do not remove nozzle unless replacement is
(2) Install nozzle cap nut (12) loosely to protect
lapped surfaces of injector body.
e. Clean. Clean injectors in a clean room on a clean
work bench. Provide a pan of clean diesel fuel and a
supply of lint-free wiping cloths. Never use hard or