Service Bulletin Number Date

3666324 01-JUN-1998

Service Bulletin

Fuel Injector Sleeve Replacement

The purpose of the Fuel Injector Sleeve Replacement Kit, Part No. 3163113, is to replace
the fuel injector sleeves of the L10, M11, and N14 engines. This kit makes it possible to
replace the fuel injector sleeves in the heads of the L10, M11, or N14 while the heads are
still installed on the engine. Labels on the tools refer only to the M11 or N14 engines, but all
references to the M11 engine will also apply to the L10 engine. Tools contained in the Fuel
Injector Sleeve Replacement Kit, Part No. 3163113 are listed in Tables 1 through 6.
Additional tools required to properly replace the fuel injector sleeves are listed in Table 7.

Included in the Fuel Injector Sleeve Replacement Kit, Part No. 3163113, and additional
tools, are the following:
Reference Number Part Number Description Quantity
Table 1 3163118 Bore Plug 1
Table 2 3163114 Hydraulic Sleeve Extractor 1
Table 3 3163119 Head Cleaning Tool 1
Table 4 3163122 Head Thickness Gauge 1
Table 5 3163125 Sleeve Seating Tool 1
Table 6 3163135 Sleeve Expansion Tool 1
Table 7 Additional Tools As Required

Table 1 - Part No. 3163118, Bore Plug

Item Part No. Description Qty.
Plug and Installation
1 3163118 1
Tool
2 3163179 O-Ring 1
Table 2 - Part No. 3163114, Hydraulic
Sleeve Extractor
Item Part No. Description Qty.
Sleeve Puller, Injector
1 3163115 1
Sleeve
Nut, Injector Sleeve
2 3163116 1
Locking
Drawbar, Injector
3 3163117 1
Sleeve
4 3163180 Cylinder, Hydraulic 1

Table 3 - Part No. 3163119, Head Cleaning

Tool
Item Part No. Description Qty.
Scraper Blade, Injector
1 3163120 1
Sleeve
Scraper Shaft, Injector
2 3163121 1
Sleeve
Plunger, Spring
3 3163182 1
Loaded
4 3163181 Collar, Set 1

Table 4 - Part No. 3163122, Head

Thickness gauge
Item Part No. Description Qty.
Indicator Tip, Injector
1 3163123 1
Sleeve
2 3163124 Gauge, Dial Indicator 1
3 3163183 Set Master 1
4 3163184 Rod, Indicator 1
Plunger, Spring
5 3163182 1
Loaded
Table 5 - Part No. 3163125, Injector Sleeve
Seating Tool
Item Part No. Description Qty.
1 3163188 Body, Cylinder 1
Hammer, Injector
2 3163126 1
Sleeve
3 3163127 Pin, Injector Sleeve 1
4 3163128 Rod, Injector Sleeve 1
5 3163130 N14 Capscrew 2
6 3163131 L10, M11 Capscrew 2
7 3163186 Adapter, L10, M11 2
8 3163185 Adapter, N14 2
9 3163132 Pin, Orientation 2
Table 6 - Part No. 3163135, Sleeve
Expansion
10 Tool Spring, Coil
3163133 1
Item Part No. Description
Belleville Washer Qty.
11 3163134 1
Pack (8)
Driver, Injector Sleeve
1 3163136 1
12 3163187 Expander
Hammer O-ring 1
13 3163189 Mandrel,
Valve, Air Control
Injector 1
2 3163137 1
Sleeve
Roller Cage, Injector
3 3163138 1
Sleeve
4 3163139 Roller, Injector Sleeve 3
Clamp End, Injector
5 3163140 1
Sleeve
Pilot Bushing, Injector
6 3163141 1
Sleeve
Clamp Rod, Injector
7 3163142 1
Sleeve
8 3163190 N14 capscrew 2
9 3163191 L10, M11 Capscrew 2
10 3163192 L10, M11 Adapter 1

Table 7 - Additional Tools

Item Part No. Description Qty.
 Table 7 - Additional Tools
Item Part No. Description Qty.
1 3823622 Hydraulic Actuator Kit 1
2 3823624 Hydraulic Hose 1
3 3398121 8- inch Scribe 1
4 3398140 Hook & Pick Set 1
Nylon Injector Bore
5 3824102 1
Brush
5/16 inch Multi-Angle
6 3399273 1
Hex Key

General Tool Maintenance

Basic tool maintenance procedures are required to keep tools in proper operating condition.
These procedures include general cleaning and lubrication instructions to keep the tools
operating freely. These maintenance procedures should be performed prior to the use of the
tools on the engine.

Special attention must be given to the screw threads of the sleeve extractor tool. The screw
threads must be coated with antisieze and the expansion cam of the expanding collet must
be coated with Lubriplate™.

The cylinder body of the seating tool must have four to five drops of light machine oil placed
in the air fitting.

The shaft threads and the rollers of the sleeve expansion tool should be lubricated with light
machine oil.

Before each use of the tools, verify that the tools are clean of debris.

Removal

CAUTION

Make sure the top of the cylinder head and

injector bores are wiped clean. Failure to
properly clean the cylinder head or injector
bore may cause damage to the cylinder
head, injector sleeve, or tools.

NOTE: A minimum distance of

approximately 432 mm [17 in] of clear
space is required over the cylinder head to
perform the procedures using these tools.
Remove the injector sleeve from the
cylinder with the smallest amount of clear
space first.

Verify the clear space requirement over the

top of the engine for use of tools.

NOTE: Tools were designed to work with

the rocker housing still installed on the
engine.

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 and remove the rocker

assemblies, push tubes, and fuel injectors
from the head as directed in the appropriate
troubleshooting and repair manual.

NOTE: All original N-Series heads will be

machined smooth between the four
expansion plugs. A reconditioned head will
have a code stamped between the four
plugs. All L10 and M11 reconditioned
heads will have a code stamped on the
forward fuel pump side of the head. Any
code designates a reconditioned head. All
reconditioned heads must be removed
from the engine and replaced with new
reconditioned heads.

Inspect the head for a reconditioned code

stamp.

WARNING
Do not pull or pry on the fan to rotate the
engine manually. Doing so can damage the
fan blades. Damaged fan blades can cause
premature fan failures that can result in
serious personal injury or property damage.

NOTE: The crankshaft rotation is clockwise

when viewed from the front of the engine.

Position the piston of the designated cylinder

in the bottom dead center position by rotating
the crankshaft with the accessory drive.

NOTE: Some injector sleeve replacement

tools require the use of two screws to
mount on the cylinder head. Some N14
cylinder heads do not have two mounting
holes. In this case, this procedure can not
be performed and the head must have its
injector sleeve replaced using procedure
02-07 in the appropriate shop manual. If the
two holes are present but do not contain
threads, stop now and tap 3/8 inch - 16
threads into all untapped screw holes
opposite the injector hold-down screw
holes.

Inspect the N14 cylinder head to make sure

that two mounting holes are available for the
injector sleeve removal and seating tools.

Clean the cylinder head area around the

injector bore of all oil, grease, and debris.
Wipe all debris, grease, or oil from the injector
bore.

Install the debris plug on the installation tool by

pressing the installation tool onto the top of the
plug tool and turning the installation tool
counterclockwise.

CAUTION

Verify proper alignment when installing or

removing tools from the cylinder head or
injector sleeves. Failure to properly align
tools may cause damage to cylinder head,
injector sleeve, or tools.

Install the debris plug vertically into the injector

opening of the head with the o-ring end
upward. Push the debris plug downward until
the tool o-ring presses through the injector
sleeve. Turn the installation tool clockwise
and remove the installation tool.

NOTE: There are two captive capscrews on

the spacer body. One is for installation on
L10 or M11 heads and the other is for
installation on the N14 head.

Loosen the locking nut at the top of the

extractor drawbar and press downward to
loosen the jaw.

Position the extractor drawbar in the injector

hole.
Install the spacer body over the extractor
drawbar and the injector hole with one screw.

NOTE: Two indicator marks are located on

the sleeve puller where the sleeve puller
aligns with the top of the spacer body.
These marks align with the top of the
spacer body when the sleeve puller stop
shoulder contacts the upper edge of the
copper sleeve in the L10, M11, or N14
heads.

Push the sleeve puller downward until the stop

shoulder is seated on the top portion of the
copper sleeve.

Tighten locking nut on top of the drawbar.

Torque Value: 108 n.m [80 ft-lb]

NOTE: The hydraulic cylinder has a full

stroke length of only two inches. The
actuator must be installed in the upright
position.

Install the hydraulic cylinder on the drawbar

with the threaded collar. Tighten hand tight
only.

WARNING
Keep hands clear of the hydraulic actuator
and sleeve puller during removal. Failure to
keep clear can result in injury to personnel.

Depress the hydraulic actuator pedal on the

side labeled PRESS and hold until the injector
sleeve is free from the head.
Depress the hydraulic actuator pedal on the
side labeled RELEASE and hold until the
hydraulic actuator is compressed.

Remove the threaded collar and the hydraulic

actuator from the sleeve puller.

Loosen the capscrew and remove the spacer

from the extractor sleeve puller and the
injector hole.

Remove the extractor sleeve puller and the

injector sleeve from the injector hole.

NOTE: A pipe wrench or vise may be

required to remove the injector sleeve from
the sleeve puller. The teeth on the sleeve
puller are helical to allow the extracted
sleeve to be unscrewed from the drawbar
sleeve puller.

Loosen the locking nut at the top of the

extractor drawbar and press downward to
loosen the jaw and remove the injector sleeve.

CAUTION

Do not use air pressure to remove debris.

Use of air pressure to remove debris may
blow debris into the water jacket causing
damage to equipment.

NOTE: Keep the debris plug in place while

cleaning the bore and combustion face.
Look for two copper rings sheared from the
injector sleeve, to be in the injector bore
and the o-ring groove.

Remove the o-ring and clean the o-ring groove

using a mechanic's pick or awl.

NOTE: Use a nylon injector bore brush,

Part No. 3824102, or equivalent, and
vacuum cleaner to remove remaining
debris from the bore.

Remove all pieces of copper and rubber that

sheered from the injector sleeve and the o-ring
during removal.

Inspect the injector bore for any debris.

CAUTION

Do not use the debris plug installation tool

to remove the debris plug from the head.
Use of the debris plug can cause damage
to the tool or head.

NOTE: Use a mechanic's pick, or similar

tool, to remove the debris plug from the
injector opening of the head.

Remove the debris plug from the injector bore

of the head.

NOTE: Dried coolant residue on the seating

steps may prevent proper sealing of the
injector sleeve.

Remove all coolant residue from the seating

steps of the injector bore using a mechanic's
pick and brush.

Inspect for worn head seating steps in the

injector bore. If the seating steps are partially
or completely worn off remove the head from
the engine for injector sleeve replacement
using procedure 02-07 in the appropriate shop
manual.

CAUTION

Make sure the set collar of the head

cleaning tool is adjusted prior to scraping
L10, M11, or N14 heads. Failure to properly
adjust as indicated on the body could result
in damage to tools and equipment.

CAUTION

Make sure that cutting edge of the head

cleaning tool scraper blade is dulled with a
honing stone prior to initial use. Failure to
dull the blade edge prior to use may result
in damage to the cylinder head fire deck.

Loosen the set screw and adjust the depth of

the head cleaning tool set collar to match the
head to be cleaned.

Tighten set screw.

Pull outward on the spring loaded plunger and

turn the top knob to the INSTALL position.

NOTE: Each of the three N14 cylinder

heads must have the fire deck of one
injector bore scraped. The L10 and M11
cylinder heads must have the fire deck of
cylinders one or six, and three or four,
scraped.

Position the injector sleeve head scraper in the

head.

Pull outward on the spring loaded plunger and

depress and rotate the top knob to the CUT
position. Allow the spring loaded plunger to
lock the cutter in position.

NOTE: The arrows and the words CLEAN

located on top of the injector head scraper
indicate the direction to turn during head
cleaning.

Turn the injector sleeve head scraper a

minimum of six turns and continue to turn until
the rotation of the tool is smooth. This will
remove the carbon from the fire deck around
the injector hole.

Pull outward on the spring loaded plunger and

turn the top knob to the INSTALL position.

Remove the injector sleeve head scraper from

the head.

NOTE: The head thickness gauge must be

calibrated to the set master for the
appropriate engine prior to use.

NOTE: The height of the N14 head is

greater than the height of the L10 and M11
heads. Make sure the injector sleeve head
thickness gauge is calibrated to the height
of the head you are working on using the
head thickness gauge set master.

Pull outward on the spring loaded plunger

located on the side of the head thickness
gauge and depress and rotate the knob on the
top to the INSTALL position.

Release the spring loaded plunger.

Position the injector sleeve head thickness

gauge in the head thickness set master.

Pull outward on the spring loaded plunger

located on the side of the injector sleeve head
thickness gauge and depress and rotate the
knob on top to the GAUGE position.

Release the spring loaded plunger.

Depress the knob on top of the injector sleeve

head thickness gauge and rotate the head
thickness gauge set master to the position
required.

Adjust the dial gauge face so that the long arm

of the gauge indicates the zero position.

Pull outward on the spring loaded plunger

located on the side of injector sleeve head
thickness gauge and depress and rotate the
knob on the top to the INSTALL position.

Release the spring loaded plunger.

Remove the injector sleeve head thickness

gauge from the head thickness gauge set
master.

NOTE: The injector sleeve head thickness

gauge measures the distance from the
combustion surface of the head to a gauge
diameter in the injector bore, located at a
point known as the 22.454 mm [0.884 in]
gauge diameter.

NOTE: Only those injector bores which

have had the fire deck scraped must be
measured.

Install the injector sleeve head thickness

gauge in the head until it rests at the gauged
diameter in the injector bore.
Pull outward on the spring loaded plunger on
the side of the injector sleeve head thickness
gauge and depress and rotate the knob on top
to the GAUGE position.

Release the spring loaded plunger and the cap

gently.

NOTE: The head thickness must be

measured three times, with the injector
sleeve head thickness gauge being rotated
120 degrees (1/3 of a turn) after each
measurement. Do not hold the injector
sleeve head thickness gauge during the
measurement.

Measure the head thickness from the

combustion surface to the 22.454 mm [0.884
in] gauge diameter. Repeat this process until
three consecutive measurements are within
0.025 mm [0.001 in] of each other.

Head Thickness Specification

mm in
L10, M11, N14 −0.1016 MIN −0.004
0.1016 MAX 0.004

Pull outward on the spring loaded plunger on

the side of the injector sleeve head thickness
gauge and depress and rotate the knob on top
to the INSTALL position.

Release the spring loaded plunger.

Remove the injector sleeve head thickness

gauge from the injector bore and install in the
head thickness gauge set master.

Verify that the injector sleeve head thickness

gauge measurement shown on the head
thickness gauge set master is between 0.0127
mm [0.0005 in] and −0.0127 mm
[-0.0005 in].

If the injector sleeve head thickness gauge

measurement is not between 0.0127 mm
[0.0005 in] and −0.0127 mm [−0.0005 in], the
complete process of measuring the head
thickness must be performed again. The
process must be performed from the point
when the injector sleeve head scraper was
removed from the head.

A measurement that exceeds 0.1016 mm

[0.004 in] indicates that the cylinder head deck
has been resurfaced. Remove the cylinder
head and replace the injector sleeves off
engine using the standard procedure.

A measurement that exceeds−0.1016 mm

[−0.004 in] indicates that there is excessive
carbon buildup on the fire deck surface of the
head. Repeat the head cleaning steps and
remeasure the head.

Installation

CAUTION

Make sure the o-ring is fully seated in the

o-ring groove and well lubricated with
vegetable oil to prevent damage to, or
movement of, the o-ring during installation.

Lubricate the new o-ring generously with

vegetable oil.

Install the new o-ring in the o-ring groove of

the injector bore.

CAUTION

Do not apply additional sealing products to

the injector sleeve during installation. Use
 of additional products may produce a
temporary seal which may break down and
leak during engine operation.

CAUTION

Use care when positioning the injector

sleeve into the injector bore. Failure to
gently insert the injector sleeve into the
injector bore could result in damage to the
injector sleeve.

NOTE: A new premachined injector sleeve,

Part No. 3411410, can be identified by a
light blue Dykem ® stripe located on the
top edge of the sleeve.

Wipe the
NOTE: new premachined
Separate adapters areinjector
used sleeve
on the
(Part M11,
L10, No. 3411410)
and N14 clean
heads. with a clean wiping
cloth.
Install the sleeve seating tool and the
Inspect the head
appropriate seating
adapter steps
into the of thebore
injector injector
and
bore to make sure that all debris
snug the two captive capscrews. has been
removed.

Position the new premachined injector sleeve

in the injector bore and gently press the sleeve
into the bore using the plug installation tool
until it rests on the head seating steps.

NOTE: One additional turn is required after

the seating tool body contacts the injector
sleeve. The additional turn applies 3336 N
[750 lb] preload required to seat the
injector sleeve.

Tighten the sleeve seating tool body by hand

until contact is felt against the injector sleeve.

Turn the sleeve seating tool body one

additional full turn.

WARNING
 Make sure the hammer trigger is in the
locked position prior to installing the remote
air control valve on the hammer. Failure to
do so may allow the hammer to trigger
prematurely, causing damage to equipment
or injury to personnel.

Position the trigger of the hammer in the

locked position by compressing the top section
of the hammer on the lower section of the
hammer and rotating counterclockwise.

Connect the remote air control valve to the air

supply.

NOTE: The remote air control valve

preloads the hammer with sufficient
pressure to perform the same production
process
Rotate ofhammer
the dropping a 18.1 kgto[40
clockwise lb] the
release
weight 88.9
hammer and mm
seat the injector sleeve.
[3.5 in]. A minimum of 551.6 kPa [80 psi] is
required to operate the hammer. Use of air
pressure more than 690 kPa [100 psi] will
cause difficulty in releasing the hammer
during use.

Open the remote air control valve and apply

air pressure to cock the hammer.

Install the seating hammer on the sleeve

seating tool body.
Remove the air hose from the air control valve.

Release the air from the air control valve.

WARNING
 The sleeve seating tool is under the
hammer spring pressure. Failure to keep
hands clear of the hammer spring face of
the spring seating tool could result in injury
to personnel.

Remove the hammer from the sleeve seating

tool.

Compress the hammer, holding the air valve

open, and rotate the trigger to the locked
position.

CAUTION

Use care when removing the sleeve seating

tool from the injector seal and head bore. If
the injector sleeve is loose or dislodged, the
entire seating procedure must be repeated
using a new premachined injector sleeve.
Failure of the injector sleeve to properly
seat may cause damage to the sleeve, the
head, or the engine.

Loosen the body of the sleeve seating tool.

Remove two capscrews and the sleeve

seating tool from the head.

CAUTION

Make sure that all pressure is removed from

the sleeve expansion tool arbor shaft rollers
prior to installation. Failure to remove all
pressure may result in damage to the
sleeve expansion tool or the head.

Loosen the coupling nut to install the sleeve

expansion tool in the head bore.

NOTE: The sleeve expansion tool mounting

adapter must be used when working on the
L10 or M11 head. The N14 head does not
require the use of the mounting adapter.

Install the adapter on the sleeve expansion

tool.

WARNING
The shaft of the sleeve expanding tool is
under spring tension. Grasp the sleeve
expanding tool firmly during installation or
removal to prevent injury to personnel.

NOTE: The sleeve expanding tool is under

spring pressure and must be pressed
downward to install the two capscrews.
Make sure that the sleeve expanding tool is
flush against the head before tightening the
capscrews.

Install the sleeve expanding tool in the injector

bore with the two capscrews.

Inspect to make sure that the clamp rod upper

locking nut is tight.

NOTE: Tightening the clamp rod sets up

the initial pressure on the arbor to expand
the injector sleeve.

While holding the arbor nut stationary, tighten

the clamp rod.

Torque Value: 7 n.m [60 in-lb]

While holding the arbor nut stationary, tighten

the arbor lower locking nut.

NOTE: An indicator pin is located on top of

the expansion tool body. It will lower as the
arbor expands the injector sleeve in the
 injector bore until flush with the expansion
tool body.

Rotate the arbor clockwise with a wrench on

the driver until the indicator pin is flush with the
body.

Rotate the arbor counterclockwise with a

wrench on the driver to relieve the pressure on
the arbor for removal.

Loosen the arbor lower locking nut.

Loosen the clamp rod three rotations

counterclockwise.

Remove the two capscrews and the sleeve

expansion tool from the injector bore.

NOTE: Use injector protrusion comparator

(Part No. 3375155) to check for injector
protrusion. Use the appropriate shop
manual to obtain the injector protrusion
specifications.

Install the injectors and all other items

removed, using the appropriate replacement
procedures in the applicable troubleshooting
and repair manual.

Refill the cooling system and operate the

engine for five minutes.

Replace the lubricating oil and filter.

Last Modified: 17-Mar-2003

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