Service Information

Document Title: Function Group: Information Type: Date:

Injector sleeves, replacing 237 Service Information 5/28/2017
Profile:
EXC, EC480D L [GB]

Injector sleeves, replacing

Op nbr 237-017

Total procedure time (hr): 10.00

Tools:
9998599 Cleaning tool
9998251 Sealing plug
9998251 Sealing plug
9998251 Sealing plug
9998251 Sealing plug
9998251 Sealing plug
9998251 Sealing plug
88800196 Flaring tool (copper sleeve)
9990006 Puller
9990262 Adapter
9996400 Impact puller
9998250 Ring
88800342 Puller
9986173 Puller
9998250 Ring
88800457 Counterhold

E-tool, see drawing E-1763

This operation also includes required tools and times for applicable parts of the following operations:

 Service positions
 Unit injector, replacing
 Coolant, change
 Valves, adjusting
 Unit injector, adjusting pretension

1. Place the machine in service position, see Service positions.

2. Remove the injectors, see Unit injector, replacing.

3. Clean the cylinder head's face thoroughly with a cleaning agent.

4. Install 9998250 Ring (2 pcs.) to prevent dirt from entering the fuel channels when the injector sleeve is removed.
 Figure 1

1. 9998250 Ring

5. Check that the rings seal off the fuel channels as shown in figure.

Figure 2

1. 9998250 Ring

6. Install five 9998251 Sealing plug.

7. Drain the coolant, see: Coolant, change

NOTE!
Connect the hose to the nipple on the engine block. Leave the drain equipment in place during the work since more
fluid may drain when the injector sleeves are removed.

Injector sleeve
NOTE!
There are different versions of injector sleeves, flat copper sleeve with washer, and stainless steel tapered sleeve.
Figure 3

Copper sleeve

Figure 4

Steel sleeve

8. Check the piston's position, there must be space in the cylinder for the tool that flares the new sleeve. Get a measuring
tool that is max. 6 mm Ø and at least 300 mm long. Insert the measuring tool in the cylinder for which the injector
sleeve is to be replaced. The tool shall bottom out against the piston 200 mm down from the cylinder head's upper
face. If needed, rotate the engine until the measurement is ≥200 mm.

9. Install 88800342 Puller and press down so that it bottoms out in the sleeve, a 'click' sound is heard. On the tool there is
a line marking at a depth of 66 mm. If the tool drops so low that the line cannot be seen it may be difficult to pull up
the sleeve since this indicates that it has been deformed. Tighten down the tool. Copper sleeve: Tighten down the
expander by tightening the nut until it stops. Steel sleeve: Tighten to torque 40 Nm (29.5 lbf ft). It is important to
tighten to correct torque if the steel sleeve is installed since it is considerably harder than the copper sleeve.
 Figure 5

1. Puller, included in the kit 88800342 Puller

2. Back-up ring, included in the kit 88800342 Puller

10. Then install 9986173 Puller. Tighten down the puller.

Figure 6

1. 9986173 Puller

11. Pull up the injector sleeve with the puller.

NOTE!
Copper sleeves: a deformed sleeve may be difficult to pull up. Try to remove 9986173 Puller, loosen 88800342 Puller,
and try to find a new grip for the jaws. Install the counterhold and pull the sleeve upwards again.
 Figure 7

1. Injector sleeve

12. Use a lint-free rag to absorb any remaining coolant.

13. Clean the cylinder head's walls. Use 9808618 Brush. 9998580 Socket should be used to prevent dirt from entering the
fuel channel. The tools are grouped in 9998599 Cleaning tool.

Figure 8

1. 9808618 Brush
2. Bolt M10, use spacer washer.
3. 9998580 Socket

14. Clean the injector sleeve's seat in the cylinder head. Use kit 9998599 Cleaning tool.
 Figure 9

1. Extension
2. Bolt M10, use spacer washer.
3. 9998580 Socket
4. Adapter screw
5. Holder brush head
6. 9808614 Brush

15. Clean the cylinder head's holes. Use tool 9808617 Brush. Use kit 9998599 Cleaning tool.

Figure 10

1. 9808617 Brush
2. Bolt M10, use spacer washer.
3. 9998580 Socket

16. Remove the other unit injectors' injector sleeves, one at a time, in the same way.

Flaring tool
For copper sleeve, use 88800196 Flaring tool (copper sleeve).
For steel sleeve, use 88800457 Counterhold.
Installing

17. For installing steel sleeve: Check that correct 88880054 flaring pin is used, it should be 120 mm long and have four
steps. Measure the pin's diameter.
 Figure 11

The figure shows flaring tool with three steps.

Measurement X should be 7.9 ±0.05 mm (0.311 ±0.00197 in)

18. NOTE!
Always use a new O-ring.

On steel sleeve: First spray Loctite 7649 or similar on the bottom of the injector sleeve according to illustration. Then
apply sealing fluid 1161059 on the bottom of the injector sleeve according to illustration.
On both versions: Lube the O-ring on the injector sleeve with soapy water.

Figure 12

Steel sleeve

19. Place the injector sleeve on the 88800457 Counterhold. Smear grease on the threads and under the nut on the
88800457 Counterhold. Screw in the pin until stop, then screw it out half a revolution.
Oil in the pin.

Figure 13

1. Pin
2. Steel sleeve
 3. 88800457 Counterhold

20. Install the unit injector's yoke to press down the injector sleeve. By holding the tap and turning the nut, the tap on the
flaring tool is pulled through the injector sleeve's point.

Figure 14

21. Install the other unit injectors' injector sleeves, one at a time, in the same way.

22. Remove 9998250 Ring.

Figure 15

1. 9998250 Ring

NOTE!
Make sure that the 9998250 Ring is not left in place, blocking any of the fuel channels.

23. Install the unit injector, see Unit injector, replacing.

NOTE!
In case of cleaning the unit injector, never use a steel scraper, steel brush, or similar on the injector nozzle. There is risk
that the injector nozzle holes may be damaged or clogged, resulting in power loss. If needed, use a rag with kerosene
or similar.

24. Adjust valves and unit injectors, see Valves, adjusting and Unit injector, adjusting pretension.

25. Fill coolant, see Coolant, change .

26. Restore the machine from service position.