ISM, ISMe, and QSM11 – 011-061   Aftertreatment Fuel Injector Coolant Test

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

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.

• Drain 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 Procedure 008-018 in Section 8.
• Disconnect the fuel line to the aftertreatment fuel injector. Refer to Procedure 011-051 in Section 11.
• Disconnect the coolant lines to the aftertreatment fuel injector. Refer to Procedure 011-051 in Section 11.
• Remove the aftertreatment fuel injector from the exhaust adapter pipe. Refer to Procedure 011-042 in Section 11.

Plug one of the coolant connections with an M16 x 1.5 plug.

Fill the nozzle area with water.

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

Apply compressed air regulated at 241 kpa [35 psi] to the opposite coolant connection.

If air bubbles are seen in the nozzle area, the aftertreatment injector has a crack that is allowing coolant to leak through.

The injector must be replaced.

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

• Remove the plug and compressed air connection from the coolant connection points.
• Install a new fibrous insulator.
• Install a new metal gasket.
• Install the aftertreatment fuel injector assembly onto the adapter pipe. Refer to Procedure 011-042 in Section 11.
• Connect the fuel line to the aftertreatment fuel injector. Refer to Procedure 011-051 in Section 11.
• Connect the coolant lines to the aftertreatment fuel injector. Refer to Procedure 011-051 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 Procedure 008-018 in Section 8.
• Start the engine, check for leaks, and verify all fault codes are inactive.