TM 5-3805-291-23-2
FUEL INJECTORS AND WIRING HARNESS MAINTENANCE - CONTINUED
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INSTALLATION - CONTINUED
6.
Install electronic fuel injector (2) and fuel injector clamp (5).
7.
Install bolt (4) in fuel injector clamp (5) and tighten to 41 7 lb-ft (55 10 Nm).
N OT E
Trace routing of wiring harness and
remove/install mounting hardware and
tiedown straps.
8.
Connect wiring harness (1) to connector (3).
9.
Connect wiring harness (1) to electronic fuel injector
(2) and tighten wiring harness to 22 2 lb-in.
(2.50 0.25 Nm).
427-C0440
10.
Install rocker arms (WP 0180 00).
CAU T I ON
DO NOT run engine until rocker arm assemblies are installed and adjusted properly, including rocker arm
adjustments for injectors. Doing so will cause engine damage.
11.
Run engine and verify correct operation (TM 5-3805-291-10).
TESTING
1.
Check for air in fuel, if this procedure has not already been performed (WP 0011 00).
WARN I N G
The electronic unit injector system uses 90 to 120V. To prevent injury to personnel, make sure electronic
unit injector system is not powered and unit injector solenoids are disconnected.
2.
Remove valve cover and look for broken parts. Repair or replace any broken parts. Inspect all wiring to solenoids. Look
for loose connections. Also look for frayed wires or broken wires. Ensure connector for fuel injector solenoid is properly
connected. Perform a pull test on wires. Inspect posts of the solenoid for arcing. If arcing or evidence of arcing is found,
remove the cap assembly. Clean the connecting posts, reinstall cap assembly, and tighten solenoid nuts to 22 + 2 lb-in.
(2.50 + 0.25 Nm).
3.
Check the valve lash setting for the cylinder of the suspect fuel injector (WP 0179 00).
4.
Ensure bolt that holds the fuel injector is tightened to correct torque. If necessary, loosen bolt that holds fuel injector and
tighten bolt to 41 + 7 lb-ft (55 + 10 Nm).
5.
Remove suspect fuel injector and check for signs of exposure to coolant. Exposure to coolant will cause rust to form on
injector. If fuel injector shows signs of exposure to coolant, remove injector sleeve and inspect. Replace injector sleeve
if injector sleeve is damaged. Check fuel injector for an excessive brown discoloration that extends beyond injector tip.
If excessive discoloration is found, check quality of the fuel. Replace seals on injector and reinstall the injector.
6.
If problem is not resolved, replace suspect injector with new injector.
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