GCLX specializes in quality remanufactured parts for heavy duty, medium duty, light duty, agriculture, off road, and school bus turbochargers, injectors, and fuel pumps.

Removal

WARNING #1

Attempting to remove the injector without first removing the fuel connector/fuel line will cause damage to the injector body and/or fuel connector/line.

WARNING #2

The fuel pump, high-pressure fuel lines, and fuel rail contain very high-pressure fuel. Do not loosen any fittings while the engine is running. Wait at least 10 minutes after shutting down the engine before loosening any fittings in the high-pressure fuel system to allow pressure to decrease to a lower level.

• Before servicing any fuel system components, (such as fuel lines, fuel pump, injectors, etc.) which could expose the fuel system or internal engine component to potential contaminants prior to disassembly, clean the fittings, mounting hardware, and the area around the component to be removed. Dirt or contaminants can be introduced into the fuel system and engine if the surrounding areas are not cleaned, resulting in damage to the fuel system and engine.
• Before servicing the fuel system, loosen the pump-to-rail line at the rail (if applicable) to vent the pressure. Keep hands clear of the line while loosening. Re-tighten the pump-to-rail line nut.
• Remove all injector wiring harnesses and/or lines. Wiring and fitting should be inspected for damage, and replaced if necessary.
• Most injectors feature a sealing washer mounted on the tip of the injector that ensures a proper seal between the injector tip and combustion chamber. The injector sealing washer can be left in the head when removing the injector, failure to remove this washer can cause premature injector failure if installed with a second sealing washer. See bulletin “Combustion Blowby” for further information.
• When removing injectors for testing and/or re-use, verify if injectors feature a trim code. If so, mark the injector to verify the cylinder it originated from to prevent runnability concerns during install or reprogramming of the trim code.

Installation

• Be cautious when installing injectors with exposed wire terminals / studs. Max torque to be applied on the wiring harness nuts is 18 in/lbs.
• Before installing, clean the injector bore and ensure only one sealing washer is installed on the injector nozzle.
• Lubricate the injector body o-ring with clean engine oil prior to installation. DO NOT use grease products, as they can obstruct critical injector orifices.
• Ensure the injector is oriented correctly in the cylinder head. If equipped, orient the injector with the gallery for the high pressure fuel connector.

CAUTION!

High pressure fuel connectors are often equipped with a built-in edge filter that is non-serviceable. Due to this, fuel connectors should also be changed out alongside the injector.

• Ensure all high pressure connectors, hold downs and/or retaining nuts are torqued to original manufacturer specifications to prevent internal fuel leakage.

Trim Codes

• Many common rail, electronic unit injectors & hydraulic unit injectors feature a unique trim code generated during the production process that determines final flow for the fuel injector.
• It is critical when replacing the injector to program the new trim code, failure to do so can cause rough idle, low power, increased fuel consumption & in severe instances engine damage.
• If reusing injectors, verify injectors are re-installed into the cylinder they were removed from to prevent reprogramming the trim codes.
• Electronic unit injectors and hydraulic unit injectors will typically feature the trim code on the injector solenoid.
• Common rail injectors will typically feature the trim code on the injector solenoid, or injector body.
• Consult the engine manufacturers service manual for engine specific instructions on installing the trim codes.

WARNING #1

If the turbocharger housings need to be rotated, housing orientations and torquing should all be performed on a work bench to ensure proper housing fitment. When rotating the housings, be sure they are fully seated against the center housing and do not become cocked.

Once the housings are set in their final positions, the bolts and v-band clamps must be tightened to the recommended torque setting and if equipped, the lock tabs bent up against each bolt head.

After orientation is completed, be sure that wheels do not contact housings when turning the wheels by hand while applying a slight side load.

1. Pre-Installation

• BEFORE installing the turbocharger, be sure you have determined the cause of failure of the original turbocharger.
• Service air cleaners and eliminate all restrictions and leaks. Replace all contaminated crank case filters.
• Inspect and remove ALL foreign materials from air inlet ducting, intake manifold, exhaust manifold, and exhaust piping.
• Replace all oil pressure and drain lines which are kinked, broken, restricted, or deteriorating.
• Change engine oil and filters.

2. Installation

• Position turbocharger on the manifold to be sure housing orientations are correct. The bearing housing drain hole must not be more than 30 degrees from the vertical center position. If orientation needs to be changed, see the caution references on the reverse side of this tag.
• Mount turbocharger to the exhaust manifold using new gasket and antiseize compound on studs and bolts.
• Connect the exhaust system. Verify there are no restrictions which might cause excessive back pressure before connecting to turbocharger.
• If equipped, bend lock plate tabs up against a flat on each bolt head (if not already bent) on bolted housing models.
• Connect air piping system to turbocharger.

3. Pre-Lubrication

• Remove all protective caps and plugs.
• Pour new engine oil into the oil inlet hole of the turbocharger.
• Connect oil feed line to inlet connection on turbocharger using a new gasket or 0-ring.
• DO NOT USE liquid gasket or sealing compounds.
• BEFORE ATTACHING oil drain line to turbocharger, CRANK ENGINE until oil flows from the oil drain hole in bearing housing. DO NOT START ENGINE.
• Attach oil drain line to turbocharger using a new gasket.

4. Operation

• Idle engine for 5 minutes. DO NOT REV.
• Check all systems for oil, air, and exhaust leaks.
• Always have operator IDLE ENGINE FOR 3 MINUTES PRIOR TO SHUTDOWN for longer turbocharger life.