Detroit Diesel 4000 Series, Service Manual, Page: 863 / 2706

SERIES 4000 12/16V SERVICE MANUAL
C 075.05.08 – INSPECTION AND REPAIR
Perform the following steps for the inspection and repair of the injector:
1. Clean all components.
2. Using the magnetic crack-testing method with fluorescent magnetic powder, inspect
injector hold down bolt and clamping element for cracks.
[a] If injector hold down bolt and clamping element are cracked, replace as necessary.
[b] If injector hold down bolt and clamping element are not cracked, continue inspection.
3. Inspect threads on injector hold down bolt and injector for ease of movement.
[a] If threads on injector hold down bolt or injector do not show ease of movement,
replace component as necessary.
[b] If threads on injector hold down bolt and injector show ease of movement, continue
inspection.
NOTE:
When inspecting injector, ensure that it is perfectly clean.
4. Visually inspect mating surfaces of hold-down clamp for wear or damage.
[a] If mating surfaces of hold-down clamp are worn or damaged, rub down with emery
cloth or oilstone.
[b] If rubbing down with emery cloth or oilstone does not remove wear or damage,
replace hold-down clamp as necessary.
[c] If mating surfaces of hold-down clamp are not worn or damaged, continue inspection.
5. Visually inspect injector O-ring surface of injector (in cylinder head) for wear or damage.
[a] If O–ring sealing or cylinder head surface of injector is worn or damaged, rub down
with emery cloth or oilstone.
[b] If rubbing down with emery cloth or oilstone does not remove wear or damage,
replace injector as necessary.
[c] If O–ring sealing and cylinder head surface of injector are not worn or damaged,
continue inspection.
6. Visually inspect DDEC injector harness connections for damage.
[a] If DDEC injector harness connections are damaged, replace as necessary.
[b] If DDEC injector harness connections are not damaged, continue inspection.
7. Visually inspect injector hole tube for wear and damage.
[a] If injector hole tube is worn or damaged, replace as necessary.
[b] If injector hole tube is not worn or damaged, continue inspection.
8. Replace C-E rings and O-rings at every assembly.
All information subject to change without notice.
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