ENGINE - Continued
(10) Be very careful with the plunger (5). After cleaning do not touch the plunger surfaces with your fingers
Check for sharp edges on that portion that rides In the gear Remove edges with 500 grit stone.
(11) Check bushing (13) bleed hole (on side) is not plugged. Keep the bushing (13) and plunger (5) together
as these are mated parts. Slip plunger into bushing Check for free movement. Replace both
components If required
(12) Inspect teeth on the control rack (10) and control rack gear (9). Check for excessive wear or damage to
(13) Check for excessive wear of the bore of the gear (9) and the gear retainer (12). Both should be a snug
fit on the flats of the plunger.
(14) Inspect the injector follower (4) for wear. If the face requires refinishing, this must be flat ground. The
distance between face and plunger slot must never be less than 1.645 in. otherwise injector timing will
be incorrect. New followers are 1.647 + 0.002 in. (41.83 + 0.05 mm).
(15) Inspect both ends of spill deflector (21) for burrs. Remove with 500 grit stone.
(16) Inspect follower spring (6) for usual defects. Check spring with tester J22738-02. Spring free length is
1.504 in. (38.20 mm). Spring wire diameter is 0 142 in. (3.61 mm). A load of 70 lb (31.8 kg) should
compress spring to 1.028 in. (26.11 mm) or greater. Replace spring if any specification is not satisfied
or spring is cracked, broken, or badly corroded.
(17) Check the seal ring area on the Injector body for burrs or scratches. Discard injector body (8) if
evidence of damage is found. Check surface which contacts the injector bushing similarly. Replace any
loose injector body plugs or dowel pin.
(18) Examine the spray tip seating surface of the injector nut and spray tip for nicks, burrs, erosion or
brinelling, Reseat the surface or replace the nut or tip If severely damaged.
(19) Inspect valve spring (16) and replace if worn or
(20) Inspect the sealing surfaces shown with a
magnifying glass. Check for burrs, nicks,
erosion, cracks, chipping or excessive wear.
Replace any component failing inspection.
(21) Examine needle valve seating area in the spray
tip for wear or damage or foreign material.
Polish the seat area with polishing stick
J22964. Coat the taper end of stick with
compound J23038 and insert directly into
center of spray tip until it bottoms. Rotate the
stick 6 to 12 times applying light pressure.
Ensure the tapered surfaces higher up in the spray tip are not contaminated with the 2-187 compound.
After lapping, wash seat with dry cleaning solvent (item 10, Appendix B). Carry out the needle valve tip
test detailed in TEST preceding.