Katerina Swanson
The Detroit 60 series fuel injector is a component of the fuel system in a Detroit Diesel engine. When removing the injector, it is important to first blow out any remaining fuel in the injector bore using clean compressed air. If the engine has an auxiliary injector tube seal, it should be replaced with a new seal. All injector nut O-ring seals are one-time-use and must be replaced to avoid leakage. The height of the injector should also be adjusted, and the intake and exhaust valve clearances should be calibrated.
| Characteristics | Values |
|---|---|
| Engine | Detroit 60 series |
| Engine Number | 06R0518567 |
| Engine Capacity | 12.7L |
| Symptoms of Faulty Injector | Rough idling, misfiring when trying to accelerate, increased fuel consumption |
| Replacement Injector Model Number | R5235695 |
| Torque Specs | 90 ft lbs |
| Valve Lash Specs | 0.660mm and 0.230mm |
| Procedure | Blow out any fuel remaining in the injector bore with clean compressed air, replace injector nut O-ring seals, install inlet and outlet fuel lines to the fittings at the rear of the cylinder head |
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What You'll Learn
Blow out fuel from the injector bore with clean compressed air
Blowing out fuel from the injector bore with clean compressed air is an important step in the process of removing a Detroit 60 series fuel injector. This step ensures that any remaining fuel or residue is cleared out before proceeding with the removal or replacement of the injector. Here is a detailed guide on how to safely and effectively complete this step:
First, it is crucial to ensure that the compressed air being used is clean and free of any contaminants. This is essential to avoid introducing new debris into the fuel injector or causing potential damage to its internal components. Verify that your compressed air source is properly filtered and suitable for this purpose.
Next, locate the injector bore, which is the opening where the fuel injector sits. Before proceeding, make sure the engine is turned off and cooled down to avoid any safety hazards or accidental activation of the fuel system. Once the engine is off and safe, carefully disconnect the fuel line from the fuel pump, following standard safety protocols for your vehicle.
Now, take your clean compressed air source and carefully direct the airflow into the injector bore. Ensure that you are wearing appropriate eye protection and gloves to safeguard against any residual fuel or debris that may be expelled during this process.
Blow the clean compressed air through the injector bore with a steady stream, maintaining a safe distance from the opening to avoid injury from any dislodged debris. Continue blowing air through the bore for a sufficient amount of time to ensure that any remaining fuel or contaminants are thoroughly cleared out.
After completing the above steps, it is important to re-inspect the injector bore and the surrounding area for any signs of remaining fuel, residue, or debris. Use a clean, dry cloth to wipe down the area and ensure that no fuel or contaminants remain. This step helps prevent issues that could arise from residual fuel or debris during the removal or installation of the fuel injector.
By following these detailed instructions, you can effectively and safely blow out fuel from the injector bore with clean compressed air, preparing you for the next steps in the process of removing or replacing a Detroit 60 series fuel injector.
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Replace injector tube seals
To replace injector tube seals on a Detroit 60 series fuel injector, follow these steps:
First, it is important to note that injector seals are one-use items and cannot be reused. All three injector nut O-ring seals must be replaced with new seals each time an injector is removed. Failure to replace the seals can result in seal leakage.
Now, to begin the replacement process:
Step 1: Remove the Rocker Shaft assemblies. Refer to the instructions for "Removal of Rocker Arm Assembly" in your Detroit 60 series manual.
Step 2: Remove the N3 injector. You can refer to the instructions for "Removal of N3 Electronic Unit Injector" in your manual.
Step 3: Drain the engine coolant. Refer to the "Cooling System" section in your manual for detailed instructions on this step.
Step 4: Install a cup tool (J-46904) into the injector bore, aligning the tool with the slots in the tube. Turn the tool counter-clockwise to remove the injector tube.
Step 5: Inspect the removed injector tube for any cracks or defects. If the tube is defective, it must be replaced. Clean the injector tube threads using a fine wire brush, being careful not to damage the cylinder head to injector tube sealing surface.
Step 6: Clean the injector tube interior sealing surface. You can use a chemical solvent for this step to ensure all debris and residue are removed.
Step 7: Inspect the O-rings for any damage or foreign material. If the O-rings are damaged or worn, they should be replaced with new ones.
Step 8: Install a new O-ring in the groove on the injector tube. A small amount of silicone-based O-ring lubrication will aid in the installation and help create a tight seal.
Step 9: Coat the threads of the injector tube with a high-temperature nickel-based antiseize lubricant. This will help protect the threads and ensure smooth operation.
Step 10: Install the injector tube onto the cup tool (J-46904). Refer to the appropriate diagram or illustration in your manual for correct installation.
Step 11: Torque the injector tube to the specified value. For the Detroit 60 series, the torque value is typically between 35-45 N·m (26-33 lb·ft). Ensure that the tip of the injector tube is flush or slightly below the fire deck.
Step 12: Reinstall the Rocker Shaft assemblies and any other components that were removed during the process. Ensure that all parts are securely tightened and aligned correctly.
By following these steps, you can effectively replace the injector tube seals on a Detroit 60 series fuel injector, helping to maintain the engine's performance and prevent leaks.
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Adjust valve clearances and injector height
Adjusting the valve clearances and injector height on a Detroit 60 Series engine is a crucial step in ensuring optimal engine performance and longevity. Here is a detailed guide on how to perform these adjustments:
Preparation:
Before beginning any adjustments, it is essential to disconnect the starting power for the engine. This safety measure ensures that the engine is not accidentally started during the adjustment process. Additionally, remove the engine valve rocker cover as outlined in the appropriate service manual for your specific Detroit 60 Series engine model.
Measuring Valve Lash and Injector Height:
On engines equipped with a Jake Brake®, it is important to measure the valve lash and injector height before removing any brake housings. Only remove the necessary brake housings to access the adjustment points. The intake and exhaust valve clearance, as well as the fuel injector height, can be adjusted using the adjusting set screw and locknut located at the valve end of the rocker arm. Refer to the “Checking Tolerance Chart” for the correct dimensions during adjustment. Ensure that the height gauge seats properly on the machined surface, with its tip in the pilot hole. Any foreign material in the pilot hole or on the machined surface may hinder the accurate setting of the injector height.
Adjusting Fuel Injector Height:
To adjust the fuel injector height, place the small end of the height gauge into the designated hole in the fuel injector body, with the flat side of the gauge facing the fuel injector plunger. Loosen the fuel injector rocker arm locknut, then turn the adjusting set screw. Adjust the screw until the extended part (flag) of the gauge just passes over the top of the injector follower. The goal is to adjust all six injectors to have the same "feel." Once this is achieved, torque the locknut to the specified range of 41-47 N·m (30-35 lb·ft). Double-check the adjustment with the height gauge, and make any necessary fine-tuning adjustments to the set screw. Finally, remove the height gauge and proceed to the next cylinder in the adjustment sequence.
Adjusting Valve Lash:
After each set of intake and exhaust valves is adjusted, move on to adjust the corresponding injector. Bar the engine over in the direction of normal rotation until the next cylinder in the adjustment sequence reaches its valve overlap period. Repeat the adjustment process for all injectors and valves, ensuring that they are all set correctly.
Reassembly:
Once all adjustments have been made, reinstall the engine rocker cover. Refer to the appropriate service manual for specific instructions on installing the rocker cover for your engine model. Finally, reconnect the starting power to the engine.
It is important to note that adjustments to valve clearances and injector height should be made with the engine stopped and cold, with an oil temperature of 60°C (140°F) or below. Additionally, on engines with a Jake Brake®, move the handle on the injector height gauge to an alternate position, 90 degrees to the shank.
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Install fuel lines to the rear of the cylinder head
To install fuel lines to the rear of the cylinder head of a Detroit 60 series engine, follow these steps:
Firstly, it is important to note that flexible fuel lines are used to facilitate the connection of lines to and from the fuel tank, minimising the effects of any vibrations. An 0.080-inch restricted orifice is incorporated in the fuel return fitting at the rear of the cylinder head to maintain fuel pressure. This restricted orifice is crucial for maintaining the proper fuel system pressure and should not be altered or substituted.
When installing the fuel lines, ensure that connections are tightened only sufficiently to prevent fuel leakage. This will prevent the flared ends of the fuel lines from twisting or fracturing due to excessive tightening.
To begin the installation, refer to the manufacturer's instructions for specific details on your engine model. Drain the cooling system and disconnect the exhaust pipe at the turbocharger, following the steps outlined in the Detroit 60 series manual. Remove the air cleaner and charge air cooler ducting from the turbocharger and intake manifold. Disconnect the turbocharger coolant supply lines, if water-cooled, as well as the oil supply and drain lines. If necessary, remove the turbocharger itself.
Next, seal the turbocharger compressor inlet and discharge with covers or masking tape. Refer to the cylinder head specifications for flatness and warpage tolerances. If the cylinder head flatness is outside the specified tolerances, it is recommended to replace it. Verify the countersink geometry and install new injector tubes, ensuring they meet the required specifications. Place the valves into the proper location, checking that the valve heads are recessed from the firedeck surface by the specified amount.
Finally, blow low-pressure compressed air into the inlet fitting for 20 to 30 seconds or until all fuel is purged from the cylinder head. Refer to the Detroit 60 series manual for further details on specific steps and torque specifications.
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Verify the repair of the electronic unit injector
To verify the repair of the electronic unit injector, there are several steps you need to take. Firstly, it is important to note that the injector must not be disassembled. Begin by cleaning the exterior of the injector with a clean solvent and drying it with compressed air. It is important not to test new or remanufactured electronic unit injectors prior to installation in the engine. The Kent-Moore® POP stand should only be used as a diagnostic tool on fuel injectors that have been removed from an engine.
Next, test the EUI using J-34760-A. Follow the procedures supplied with this tool. Depending on the results of the test, you may need to reuse or replace the injector or injector and solenoid. Inspect the O-rings for any damage or foreign material and replace them if necessary. Inspect the fuel injector tubes at the injector seat and replace them if required.
If you are working with a DDEC III/IV engine, record the injector calibration code from the load plate with the proper cylinder location. Install the valve rocker cover. You should also adjust the intake and exhaust valve clearances and injector height.
Finally, to determine if the replaced fuel injector has resolved the misfiring cylinder condition, start the engine and operate it at the engine speed range where the misfiring occurred.
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Frequently asked questions
Symptoms of a failure in the fuel system include idling rough, misfiring when trying to accelerate, and increased fuel consumption.
Using clean compressed air, blow out any fuel remaining in the injector bore.
If the injector is removed, all three injector nut O-ring seals must be replaced with new seals. Injector seals are one-use items and cannot be reused.
