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    QSK23 - Injector Mark Test

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    theunauthorised

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    © All Rights Reserved
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    QSK23 - Injector Mark Test

    Uploaded by

    theunauthorised
    31 views9 pages

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    © © All Rights Reserved

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    PDF, TXT or read online from Scribd

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    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    31 views9 pages

    QSK23 - Injector Mark Test

    Uploaded by

    theunauthorised

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 9

    Initial Check

    Misfire Using Heat Indicator Marker

     WARNING 

    The engine temperature, when performing in-chassis


    exhaust temperature testing, can be excessive. To reduce
    the possibility of serious injury wait until the engine
    coolant temperature is below 50°C [122°F].

    Note : This procedure may not be effective when the


    symptoms occur only at low idle or when the engine is
    cold.

    If the engine exhibits symptoms of a possible injector not


    firing, perform the following check:

    Operate the engine to normal operating coolant


    temperature of 80°C [180°F].
    Stop the engine and allow the exhaust manifold to cool for
    10 minutes.
    Apply a mark (1) using a 204°C [400°F] temperature
    indicator marker, Part Number 3165163, on the surface of
    all exhaust manifold ports. The mark should be as close to
    the cylinder head as possible, but not directly on the
    exhaust manifold mounting flange.
    Start the engine and operate under light load for a short
    time. Do not operate the engine under heavy load or for
    an extended period of time as this may cause inaccurate
    results.

    If the 204°C [400°F] mark melts (1) the color will disappear and
    leave only a transparent glazed appearance where the mark
    was. This indicates that the cylinder is operating to a
    temperature above 204°C [400°F].
    If the 204°C [400°F] mark does not melt (2) the mark color
    remains present. This indicates that the cylinder is not
    operating to temperature of 204°C [400°F], indicating a
    possible injector malfunction. For additional troubleshooting
    information, go to Engine Runs Rough or Misfires
    troubleshooting symptom tree in Section TS.
    Note : It is not recommended to use the temperature
    indicator markers to troubleshoot for cylinders that are
    operating too hot.

    Check the injector s (mechanically actuated) when it is


    suspected they were run dry (without fuel).

    Remove the rocker lever covers and check to be sure all of the
    injector links are intact. If they are intact, install the rocker
    lever covers. If they are not intact, follow the injector
    inspection step in this procedure.
    Warm up the engine by running at high idle to stabilize the
    exhaust temperature. If the exhaust temperatures are within
    38°C [100°F], then all injector s are firing and working
    correctly.

    Flourescent Tracer Dye Test


    Run the engine until the water temperature is above 80°C
    [180°F].

    Remove the fuel pump return and supply lines and install a 50
    litre [15 gallon] isolated fuel supply tank.
    Add one unit of fluorescent tracer, Part Number 3376891, to
    each 38 litres [10 gallons] of fuel.

    Preheat the black light.

    Remove the rocker lever cover mounting hardware, but do not


    remove the rocker lever covers.

    Idle the engine for 5 to 10 minutes or until normal operating


    temperature is reached to allow the dye to circulate through
    the fuel system.

    Shut the engine OFF.


    Immediately remove the rocker lever cover.

    Use the black light to inspect each cylinder head.

    Some leakage around the injector is normal.

    If an abnormal amount of leakage is detected, replace the


    injector or injector o-rings.

    Preparatory Steps
     WARNING 
    Depending on the circumstance, fuel is flammable. When
    inspecting or performing service or repairs on the fuel
    system, to reduce the possibility of fire and resulting
    severe personal injury, death, or property damage, never
    smoke or allow sparks or flames (such as pilot lights,
    electrical switches, or welding equipment) in the work
    area.

     CAUTION 
    Do not spill or drain fuel into the bilge area when
    disconnecting or removing fuel lines, replacing filters,
    and priming the fuel system. Do not drop or throw filter
    elements into the bilge area. The fuel and fuel filters must
    be disposed of in accordance with local environmental
    regulations.

    Remove the rocker lever cover. Refer to Procedure 003-


    011 in Section 3. (/qs3/pubsys2/xml/en/procedures/89/89-
    003-011.html)
    Remove the rocker lever assembly. Refer to Procedure
    003-009 in Section 3.
    (/qs3/pubsys2/xml/en/procedures/89/89-003-009.html)

    Remove
    Note : The hold-down clamp can not be removed until
    the injector is removed.
    Remove the injector hold-down capscrew. Remove the
    injector and clamp.

    Use injector removal/installation tool, Part Number 3824830,


    to remove the injector s. Insert the pin of the tool in the hole
    provided in the body of the injector . The hole faces the front
    of the engine.
    Note : If the injector puller is not available, carefully
    use a prybar. Pry upward on the injector against the
    cylinder head.
    Cover the injector bore to prevent foreign objects from
    entering the cylinder.

    Clean and Inspect for Reuse


    Use a lint-free cloth to clean the exterior of the injector .

    Remove the sealing ring. Note cylinder location and thickness.

    Discard sealing ring


    Note : Oversize sealing rings are available to adjust
    injector protrusion in resurfaced and Recon® cylinder
    heads. Refer to Procedure 002-022 in Section 2.
    (/qs3/pubsys2/xml/en/procedures/89/89-002-022.html)
    Note : Recon® cylinder heads are marked to identify
    which sealing ring should be used. Refer to Procedure
    002-004 in Section 2.
    (/qs3/pubsys2/xml/en/procedures/89/89-002-004-
    tr.html)

    New o-rings must be installed in the correct order on the


    injector . Take note of the o-ring color and orientation prior to
    removal.

    Remove o-rings 1, 2, 3, and 4.

    Use a lint-free cloth. Clean the exterior of the injector .

    Carefully check the area where the sealing ring touches the
    injector .
    Inspect o-ring grooves for damage.

    Inspect injector body and cup retainer for cracks or other


    damage.
    Inspect injector links for excessive wear, pitting or scoring on
    the ball ends, and other damage.
    Note : If the link is damaged or pitting and scoring can
    be seen or felt, the link must be replaced.

     WARNING 
    When using solvents, acids, or alkaline materials for
    cleaning, follow the manufacturer's recommendations for
    use. Wear goggles and protective clothing to reduce the
    possibility of personal injury.

    Use solvent when cleaning the filters. The screens must be


    thoroughly dry prior to installation.

    Check the rail (6) and timing (7) filter screens for debris, tears,
    or punctures. Replace the filter screens if damaged or dirty.

    Check the rail (6) and timing (7) filter screens for proper
    installation.

    The filter screens must be securely snapped into the correct


    position.

    Use a small screwdriver to remove the filter screen by gently


    prying up on the connector clip.

    Wrap the filter screen around the inlet groove.


    A properly secured connector will create a single snapping
    sound.
    Apply pressure on the filter screen connector clip.

    Install
    Do not lubricate the o-rings until the injector is ready for
    installation in the cylinder head.

    Install four new o-rings on the injector . Do not twist the o-


    rings.

    O-ring (1) is brown and is smaller in diameter than the other


    three.

    O-ring (2) is black.


    O-ring (3) is brown and is larger in diameter than (1), but has a
    smaller cross section than o-ring (4).

    O-ring (4) is brown and is the largest in diameter and cross


    section.

    Install a new, proper thickness sealing ring which corresponds


    to the cylinder location noted during removal.
    Note : If installing an injector for the first time into a
    resurfaced cylinder head, use the following procedure to
    determine proper sealing ring thickness. Refer to
    Procedure 002-022 in Section 2.
    (/qs3/pubsys2/xml/en/procedures/89/89-002-022.html)

    Use clean lubricating engine oil (15W-40) to lubricate the o-


    rings.
    Install the hold-down clamp on the side of the injector .

    Install the injector and hold-down clamp in the cylinder head.

    Note : If the injector installation tool, Part Number


    3824830, is not available, use a 40 mm [1 9/16 in]
    socket with an extension and a rubber mallet to install
    the injector .
    Use injector installation tool, Part Number 3824830, to set the
    injector in the bore.

    The slide hammer will make a dull sound when the injector is
    seated properly.

    Use clean engine oil to lubricate the injector hold-down


    capscrew.

    Install and tighten the injector hold-down capscrew.

    Torque Value: 54 n•m [ 40 ft-lb ]

    Finishing Steps
    Install the rocker lever assembly. Refer to Procedure 003-
    009 in Section 3. (/qs3/pubsys2/xml/en/procedures/89/89-
    003-009.html)
    Adjust the valves and injector s. Refer to Procedure 003-
    006 in Section 3. (/qs3/pubsys2/xml/en/procedures/89/89-
    003-006.html)
    Install the rocker lever cover. Refer to Procedure 003-011
    in Section 3. (/qs3/pubsys2/xml/en/procedures/89/89-003-
    011.html)
    Operate the engine and check for leaks.

    Last Modified: 29-Apr-2014

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