Remove check ball (8) from top of
Repair. Proceed as follows:
(1) Replace injector link (3) if worn excessively.
(2) Check closely for metal seizure. As a rule
this is the only true indication of scuffing or
(3) Narrow streaks running the length of the
plunger (7) usually are the result of the
varying thickness of penetrant treatment
used to prevent rusting. Plunger is
disruption is evident.
(4) Test spring tension, on spring tester device
measurements of spring lengths and applied
load by means of standard and dial indicator
gauge. Load required to compress spring to
1.663 inches (42.2 mm) is 143.25 pounds
(65 kg) minimum to 158.75 pounds (72 kg)
maximum. Worn limit is when 138 pounds
(63 kg) is required to produce the spring
length. If spring does not compress at right
load limit, replace spring.
(5) Inspect injector spray holes and tip with
magnifying glass. Compare with new cup.
Discard cup if cup shows abrasive wear,
corrosion damage, or enlarged or distorted
(6) Using a flat steel plate and "bluing" check
injector cup barrel surface for flatness.
(7) Check cup retainer for nicks or burrs which
could prevent proper seating with sleeve in
(8) Inspect injector barrel plunger bore for
scoring. If injector will pass leakage test,
barrel is usable. If leakage was too high,
barrel and plunger must be replaced.
(9) Use strong magnifying glass to check for
burrs, carbon, and distorted radii in orifice
(13). If metering orifice shows signs of
damage, replace orifice.
following using any new parts required for
(1) Drop check ball (8) into top of barrel (7).
Be certain all mating surface parts are
clean and free of burrs or other
imperfections which could result in
incorrect flow or torque. Lap to repair.
(2) Hold barrel (7) with check ball (8) up and
place new adapter spiral pins (9) into barrel
(3) Turn adapter (15) and barrel (7) with barrel
up and place cup (6) on barrel (7).
(4) Lubricate cup retainer threads (5) and cup
flange contact area with 20 or 30W lube oil
and assemble to adapter. Screw retainer
(5) down finger tight and loosen 1/4 turn.
(5) Immerse injector plunger (7) in clean
injector test oil and install in adapter without
(6) Insert injector into fixture.
(7) Slide body wrench over flats on injector
(8) Place retainer wrench on injector retainer.
(9) Activate air cylinder on holding fixture to
align cup and plunger.
Tighten cup retainer (5) with crowfoot
wrench and retainer wrench to 50
footpounds (68 joules).
Remove injector from loading fixture
being careful not to hit cup on stud.