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Instruction Sheet

HEUI Seal Installation Instructions

4328470R1

Application
MaxxForce® DT466
MaxxForce® DT530

Kit Contents

Description Quantity
Upper Back-Up Ring (Steel) 1
Upper Cushion Ring (Black) 1
Upper O-Ring (Dark Blue) 1
Middle Seal (Pink) 1
Lower O-Ring (Orange) 1
Injector Gasket(s) (Copper and / or Stainless Steel) 1
Instruction Sheet 1

WARNING: To prevent personal injury and / or death, read all safety instructions in the “Safety
Information” section of the Engine Service Manual or Engine Diagnostic Manual.

WARNING: To prevent property damage, personal injury, and / or death, park vehicle on a hard, flat
surface, turn engine off, set parking brake, and install wheel chocks to prevent vehicle from moving in
either direction.

WARNING: To prevent personal injury and / or death, make sure the engine has cooled before
removing components.

WARNING: To prevent property damage, personal injury, and / or death, remove ground cable from
negative terminal of main battery before disconnecting or connecting electrical components. Always
connect ground cable last.

WARNING: To prevent personal injury and / or death, always wear safe eye protection when
performing vehicle maintenance.

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Read all safety instructions in the "Safety Information" section of the appropriate Engine Service or Diagnostic Manual.
Follow all warnings, cautions, and notes.
© 2017 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Procedure
Seal and Groove Identification

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0000414124

Figure 1. Fuel Injector Seals, Rings and Grooves


1. Upper back-up ring (steel)
2. Upper cushion ring (black)
3. Upper O-ring (dark blue, but may appear black in certain lighting conditions)
4. Middle seal (pink)
5. Lower O-ring (orange)
6. Injector gasket(s)

Seal Removal
NOTE: If this seal kit was included as part of a remanufactured injector assembly, skip this section and
proceed to section: FUEL INJECTOR SEALS AND O-RINGS.
NOTE: Rings and seals should be replaced each time the fuel injector is removed. If any fuel injectors
have damaged rings and seals, all fuel injectors should be removed and have their rings and seals
replaced. Care must be taken not to scratch seal grooves on fuel injector body while removing seals.
NOTE: Unless damaged, leave original steel back-up ring, in uppermost groove, on fuel injector and do
not replace.
1. Park vehicle on a flat surface.

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© 2017 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Seal Removal (cont.)
2. Shift transmission to Park or Neutral and set parking brake.
3. Install wheel chocks.

CAUTION: To prevent engine / component damage, ALWAYS drain the supply manifold oil and
fuel rails completely prior to removing the fuel injectors. This prevents leaching into the cylinder bore
when the fuel injector is removed. Fluid trapped in the cylinder can cause severe mechanical damage
to engine should a hydrostatic lock-up occur when engine is cranked with the starter.
4. Remove fuel injectors. Refer to appropriate engine service manual for instructions.
5. Remove fuel injector gasket from bottom of fuel injector.
6. Using a wooden or plastic tool, lift lower O-ring seal out of its groove. Cut seal and remove.
7. Using a wooden or plastic tool, lift middle one or two seals out of middle groove. Cut seal(s) and remove.
NOTE: This kit contains an improved single middle seal (pink), which replaces the original two middle
seal combination. This single seal should be installed whether the injector originally had two seals
or one.
8. Using a wooden or plastic tool, lift upper O-ring seal out of its groove. Cut seal and remove.
9. Using a wooden or plastic tool, lift upper cushion ring out of its groove. Cut ring and remove.
NOTE: The following step is optional.
10. If steel back-up ring is damaged, lift one corner of upper back-up ring from its groove, slide rest of back-up
ring from its groove and over tip of fuel injector.

Installation of Fuel Injector Seals and O-Rings


NOTE: Make sure fuel injector is clean and free of debris. Place fuel injector into holder rack ZTSE4299
where it will be protected from debris and damage.
Upper Groove

1. Locate upper groove rings and O-ring seal (Figure 1, Item 3).
2. Lightly lubricate rings and O-ring seal with new, clean engine oil.
NOTE: The back-up ring acts like a spring. Care must be taken when installing this part. Do not twist
the ring. Ring flatness is important.
3. Gently spread to gap and slide steel back-up ring over body of fuel injector up to the large diameter, just
below upper groove.

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© 2017 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Installation of Fuel Injector Seals and O-Rings (cont.)

0000414125

Figure 2. Upper Groove — Back-Up Ring


1. Back-up ring

4. Insert one end of back-up ring (Figure 2, Item 1) into upper groove and maneuver ring into position.

4328470R1 4
© 2017 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Installation of Fuel Injector Seals and O-Rings (cont.)

1 2

0000414126

Figure 3. Upper Groove — Cushion Ring


1. Back-up ring
2. Cushion ring

NOTE: Ensure that cushion ring does not twist during installation.
5. Slide cushion ring (Figure 3, Item 2) over fuel injector and position into upper groove. Ensure cushion ring
is positioned against back ring (Figure 3, Item 1).

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© 2017 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Installation of Fuel Injector Seals and O-Rings (cont.)

1 2 3

0000414127

Figure 4. Upper Groove — O-Ring


1. Back-up ring
2. Cushion ring
3. O-ring

NOTE: Make sure that the O-ring seal does not twist during installation.
6. Slide fuel injector upper O-ring seal (Figure 4, Item 3) over injector and into upper groove. Ensure seal is
positioned against previously-installed cushion ring (Figure 4, Item 2) and back-up ring (Figure 4, Item 1).

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© 2017 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Installation of Fuel Injector Seals and O-Rings (cont.)
Middle Groove

0000414128

Figure 5. Middle Groove


1. O-ring

1. Locate middle groove O-ring seal (Figure 5, Item 1).


2. Lightly lubricate seal with clean engine oil.
NOTE: Ensure that middle fuel indicator seal does not twist or overstretch during installation. Ensure
that seal slides onto injector. Do not roll seal.
NOTE: Approximately 10 minutes after seal has been installed, it should return to its normal shape.
Check for proper fit; seal should be trapped in middle groove, as shown in Figure 5, to ensure that it will
not slide out of groove during injector installation into cylinder head.
3. Slide middle fuel injector seal over fuel injector and push into middle groove. Care should be taken to
minimize the amount and length of time that seal is expanded during installation. Ensure that middle fuel
injector seal is positioned against groove.

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© 2017 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Installation of Fuel Injector Seals and O-Rings (cont.)
Lower Groove

0000414129

Figure 6. Lower Groove


1. O-ring

1. Locate lower O-ring groove seal.


2. Lightly lubricate O-ring seal with clean engine oil.
3. Slide middle fuel injector seal over fuel injector body and into lower engine. Make sure lower fuel injector
O-ring seal (Figure 6, Item 1) is up against groove (Figure 6, Item 1).

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© 2017 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Installation of Fuel Injector Seals and O-Rings (cont.)

0000414130

Figure 7. Sealing Face


1. Injector gasket

NOTE: Refer to appropriate service manual to determine which gasket to use.


NOTE: After all seals have been installed on injector(s), wait approximately 10 minutes before installing
the injector(s) back into cylinder head. This will allow enough time for seals to recover back to their
correct diameter to ensure ease of installation and proper seal function.
4. Apply light coat of clean grease to injector gasket (Figure 7, Item 1) and press onto fuel injector.

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© 2017 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Installation of Fuel Injector Seals and O-Rings (cont.)

CAUTION: To prevent injector tip failures and damage to internal injector components, a procedure
that primes the fuel system before starting the engine must be followed. When the fuel injection system
is dry after engine service, cranking the engine to start without priming the fuel system will result in an
overload condition in the injector tips and other injector components. This overload occurs because
there is no fuel present to cushion the needle valve as it lifts and seats. To avoid this condition, follow the
procedure below after performing any maintenance that may allow air to enter the fuel system, including
fuel filter replacement.
Fuel System Priming Procedure
1. Disconnect the injector harness at valve cover.
2. Use hand primer to fill fuel system. (Pump until hand primer becomes too hard to depress by hand.)
3. Crank engine three times for 15 seconds each. Re-apply hand primer after each crank cycle.
4. Once hand primer remains difficult to depress after the 15 second crank, reconnect injector harness and
start engine.
5. Clear fault codes 513 (low side to bank 1 open) and 514 (low side to bank 2 open) that were logged by
cranking engine with injector harness disconnected.

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© 2017 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.