ISM, ISMe, and QSM11 – 011-042   Aftertreatment Fuel Injector

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

• Drain the coolant.
• For Signature™, ISX, and QSX15 engines, use the following procedure in the Signature™, ISX, and QSX15 Service Manual, Bulletin 3666239. Refer to Procedure 008-018 in Section 8.
• For ISM, ISMe, and QSM11 engines, use the following procedure in the ISM, ISMe, and QSM11 Service Manual, Bulletin 3666322. Refer to Procedure Procedure 008-018 in Section 8.
• Disconnect the fuel lines and coolant lines.
• Disconnect the wiring harness from the aftertreatment injector.
• Remove the adapter tube and injector as an assembly. Refer to Procedure 011-043 in Section 11.

Remove the adaptor tube gasket.

Remove the capscrews holding the injector.

Remove the injector assembly.

Cut the EZ tie holding the injector harness to the heat shield.

Discard the metal gasket.

Discard the fibrous insulator.

Remove the capscrew spacers.

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.

Inspect the injector tip.

Some carboning can occur on the tip of the injector.

Spray the tip of the aftertreatment fuel injector with carburetor cleaner. When spraying, focus the spray on the tip of the injector. Use enough carburetor cleaner to fill the cavity surrounding the tip and to cover the tip.

Allow the carburetor cleaner to sit for 15 seconds so that it can break down and penetrate the debris that has collected in the tip area.

NOTE: Carburetor cleaner is the most effective solvent for this procedure. Do not substitute any other cleaning solvent.

CAUTION  Use only a stiff brass brush with undamaged bristles to clean the tip of the aftertreatment fuel injector.

CAUTION  The use of a brush with damaged bristles will not be as effective.

CAUTION  The use of a steel wire brush or a steel wire wheel will cause permanent damage to the aftertreatment fuel injector.

Use a brass brush to agitate the carburetor cleaner, focusing on the tip of the injector.

Repeat spraying and brushing for 1 minute. Often the carbon will be removed from the tip in a short period, but cleaning for a full minute will remove the carbon built up in the nozzle.

NOTE: The carbon this procedure is attempting to remove can often not be seen with the unaided eye. This carbon builds up in the nozzle tip area of the injector.

Inspect the injector tip for cracks or other damage. Replace if necessary.

Clean the adapter tube injector mounting surface. Refer to Procedure 011-043 in Section 11.

Use safety solvent to clean the capscrews.

Clean the capscrews thoroughly with a wire brush, a soft wire wheel, or use a non-abrasive bead blast to remove deposits from the shaft and the threads.

Inspect the capscrews for damaged threads, corroded surfaces, or a reduced diameter (due to capscrew stretching).

Replace if necessary.

Inspect the harness and connector pins for the following:

• Loose connector
• Corroded pins
• Bent or broken pins
• Pushed back or expanded pins
• Moisture in or on the connector
• Missing or damaged connector seals
• Dirt or debris in or on the connector pins
• Connector shell broken
• Wire insulation damage
• Damaged connector locking tab.

Use the following procedure for general inspection techniques in the CM871 and CM876 Electronic Control Systems, ISX and ISM Engines Troubleshooting and Repair Manual, Bulletin 4021560. Refer to Procedure 019-361 in Section 19.

Inspect the heat shield for the following:

• Cracks
• Dents

Replace if necessary.

Attach the heat shield to the injector.

Install a new high temperature EZ tie to hold the injector harness to the heat shield.

Install a new fibrous insulator.

Install a new metal gasket.

NOTE: The fibrous insulator will be against the injector.

Install the aftertreatment injector onto the adapter pipe.

Apply a coat of high temperature anti-seize compound to the capscrews.

Install the capscrews and spacers.

Attach the heat shield to the injector.

Install a new high temperature EZ tie to hold the injector harness to the heat shield.

Install a new fibrous insulator.

Install a new metal gasket.

NOTE: The fibrous insulator will be against the injector.

Install the aftertreatment injector onto the adapter pipe.

Apply a coat of high temperature anti-seize compound to the capscrews.

Install the capscrews and spacers.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

• Connect the fuel line and coolant lines. Refer to Procedure 011-051 in Section 11.
• Connect the adapter pipe to the turbocharger. Refer to Procedure 011-043 in Section 11.
• Connect the wiring harness to the aftertreatment injector.
• Fill the cooling system.
• Use the following procedure in the Signature™, ISX, and QSX15 Service Manual, Bulletin 3666239. Refer to Procedure 008-018 in Section 8.
• Use the following procedure in the ISM, ISMe, and QSM11 Service Manual, Bulletin 3666322.Refer to Procedure 008-018 in Section 8.
• Start the engine and check for leaks.

If damage resulted in coolant, oil, excessive fuel or excessive black smoke entering the exhaust system, the aftertreatment system must be inspected. Use the following procedure in the ISM, ISMe, and QSM11 Service Manual, Bulletin 3666322. Refer to Procedure 014-013 in Section 14.