WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Disconnect the batteries. Refer to the OEM service manual.
• Remove the injectors. Refer to Procedure 006-026 in Section 6.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

Use injector sleeve puller, Part Number ST-1244, to remove the injector sleeves from the cylinder head.

Install the puller in the injector sleeve with the legs of the bridge against the cylinder head.

Install the driver, Part Number ST-1244-8, against the large nut on the puller, as illustrated.

Hit the driver with a mallet to push the forming collar into the injector sleeve.

Remove the driver from the puller.

Tighten the small nut.

Turn the large nut clockwise to pull the injector sleeve from the cylinder head.

Loosen the nuts and remove the old injector sleeve from the puller.

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.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Remove the injector sleeve o-ring from the injector bore in the cylinder head. Discard the o-ring.

Use solvent to clean the injector bore. Dry with compressed air.

Inspect the grooves (steps) in the bottom of the injector bore.

If the grooves (steps) are damaged, use pilot, Part Number ST-884-6, holder, Part Number ST-884-1, and cutting tool, Part Number ST-788, to machine the grooves (steps) in the bottom of the injector bore.

Install the bead cutting tool and the cylinder head in a drill press. Set the drill press speed at no more than 75 RPM.

Use a cutting oil to lubricate the cutter head.

Carefully machine the bottom of the bore until the grooves (steps) are smooth.

Clean the metal particles from the injector bore.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

Use vegetable oil to lubricate the injector sleeve o-ring.

Install the o-ring (1) into the groove of the injector sleeve bore.

Use an injector sleeve driver, Part Number ST-1227, to push the injector sleeve into the cylinder head. Do not hit the driver with a hammer. Remove the sleeve driver.

Install an injector sleeve holding tool, Part Number ST-1179, into the injector sleeve and tighten the nut.

Install the injector sleeve driver against the holding tool mandrel. Hit the driver two moderate blows with a hammer to seat the sleeve in the bore.

Remove the driver and tighten the injector sleeve holding tool nut again.

Use injector sleeve expander, Part Number ST-880, to expand the upper section of the injector sleeve.

Adjust the expander roller edge (1) and the collar (2) to the clearance specified.

The rollers on the sleeve expander must extend 13.0 to 15.0 mm [0.50 to 0.60 in] below the top of the injector sleeve. Do not extend the rollers more than 15.0 mm [0.60 in] below the top of the sleeve.

Install the expander in the injector sleeve and turn the mandrel with an inch-pound torque wrench.

Remove the expander and holding tool from the injector sleeve.

Use pilot, Part Number ST-884-6, holder, Part Number ST-884-1, and injector seat cutter, Part Number ST-884-3, to cut the injector seat.

Install the injector sleeve cutter and cylinder head in a drill press.

Use a generous amount of cutting oil to lubricate the cutter head during the machining operation, to prevent galling of the injector sleeve.

Carefully machine the injector sleeve until the sealing area is smooth.

Clean the metal particles from the injector sleeve bore.

NOTE: Support the cylinder head to prevent damage to the injector tip that protrudes from the combustion face.

Apply a light film of bluing compound to the outside diameter of the injector at the injector seat area.

Bluing compound can effectively be applied with your finger or with a brush.

Install the injector in the cylinder head without o-rings.

Place a 30.5 mm [1.20 in] thick block under the injector hold down clamp. This represents the rocker housing.

Tighten the injector hold-down capscrews.

Turn the cylinder head over and use a gauge block, Part Number 3823495, to measure the injector tip protrusion.

Injector Tip Protrusion

NOTE: If the injector tip protrusion does not meet the specifications, the injector sleeve must be machined again.

Remove the injectors from the cylinder head and check the pattern of the bluing compound in the injector sleeve.

The bluing pattern in the injector seating area (1) must be visible 360 degrees around the seating area.

The injector bore seating width (2) must be a minimum of 1.52 mm [0.060 in].

NOTE: If the injector protrusion is more than the maximum specification, or if the injector sleeve bluing pattern does not meet the specifications given, the injector sleeve must be replaced.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

NOTE: Inspect the cylinder head for leaks after the new injector sleeves have been installed. Refer to Procedure 002-004 in Section 2.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Remove the injectors. Refer to Procedure 006-026 in Section 6.
• Connect the batteries. Refer to the OEM service manual.
• Operate the engine and check for leaks.