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Major System: ENGINES Created: 6/24/2014

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Title : Maxxforce 15L Injector Sleeve Replacement

Applies To : 2011 Maxxforce 15L

CHANGE LOG:

2015/6/17 - Updated parts table and steps to use Loctite 515 instead of Loctite 620 compound

2014/10/28 - Updated format

2014/08/11 - Updated SRT information

2014/08/04 - Launch to field

DESCRIPTION:

This article provides the procedure for injector sleeve replacement on the Maxxforce 15L engine. If diagnosing one or more of the

symptoms listed below and you have determined that the injector sleeve is the root cause, follow the repair procedure below.

SYMPTOMS:

- Coolant leak to fuel

Fuel in coolant

Fuel in lube oil

- Compression to fuel

SPECIAL TOOLS:

Tool Description Tool Number

Maxxforce 15L Tool Kit - TL2900007 ZTSE5028

Injector Sleeve Kit ZTSE6095

Fuel Injector Kit ZTSE6102

SERVICE PARTS INFORMATION:

Kit Description Part Number Quantity Required Notes

Page 1 of 14IK1201150 Maxxforce 15L Injector Sleeve Replacement

7/1/2015https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID...

To prevent damage to the vehicle or engine, read all safety instructions in the Safety information section

of the Service and Diagnostic Manual for the application that is being serviced

Kit, Injector Sleeve 7092980C91 6 Remove Loctite 620 in kit - use Loctite 515

Kit, Injector Seal Kit 3014430C91 6

Tube Assy Rail to Injector 3007916C2 1






Loctite 515 PTX51531 1Replaces Loctite 620 that comes in Injector

Sleeve Kit

REPAIR PROCEDURE

To prevent personal injury or death, read all safety instructions in the Safety Information section of the

Service and Diagnostic Manuals for the application that is being serviced

REMOVAL:

1. Remove the rail to injector tube assembly, valve brake actuator assembly, rocker arm assembly and lost motion

pedestals, following the removal procedures in the EGES-510 Engine Service Manual. Discard the rail to injector tube assembly.

2. Remove the highpressure connector retaining nut

3. Remove high pressure connector from cylinder head

4. Remove the 3/8 -16 x 4 hex bolt, 9.8 x 15.85 x 37.6 spacer, and injector clamp for affected cylinders



Figure 1: Installation of threaded legs into lost motion pedestal bolt holes

Item 1 - ZTSE6095-4 Threaded Legs

5. Install the two threaded legs (Figure 1, Item 1)--with wrench flats up--into lost motion pedestal bolt holes. Hand tighten

threaded legs.



Figure 2: Installation of ZTSE6102-1 jaw puller assembly on fuel injector

Item 1 - ZTSE6102-1 Jaw Puller Assembly

Item 2 - Fuel Injector

6. Install the jaw puller assembly onto the fuel injector (Figure 2, Item 1).



Figure 3: Installing ZTSE6095-3 threaded leg into injector hold-down bolt hole

Item 1 - ZTSE6095-3 Threaded leg

Item 2 - ZTSE6102-1 Jaw Puller Assembly Installed on fuel injector

7. Install ZTSE6095-3 threaded leg into the injector hold-down bolt hole. Hand tighten threaded leg.



Figure 4: Installing Tee Plate

Item 1 - ZTSE6095-1 Tee plate

Item 2 - Threaded legs (ZTSE6095-3, ZTSE6095-4)

Item 3 - ZTSE6102-1 Jaw puller assembly

8. Install Tee plate ZTSE6095-1 over threaded legs and jaw puller assembly

9. Install three nuts on threaded legs and hand tighten



Figure 5: Installed tee plate

Item 1 - Hand tightened nuts on threaded legs

Item 2 - 5/8 washer and 5/8-18 nut on ZTSE6102-1 jaw puller assembly

10. Install 5/8 washer and 5/8-18 nut onto jaw puller assembly ZTSE6102-1 and turn clockwise until injector is out.

11. Remove three nuts from threaded legs



Figure 6: Removed Injector

Item 1 - ZTSE6102-1 Jaw puller assembly

Item 2 - Fuel injector

12. Lift Tee plate vertically and then remove injector assembly from jaw puller assembly

13. Place injector into fuel injector rack holder ZTSE4299B

Continue with procedure to remove fuel injector sleeve

14. Thread the sleeve puller (ZTSE6095-2) into the fuel injector sleeve.

15. Place the Tee plate (ZTSE6095-1) over the sleeve puller and threaded legs. Install the three nuts on threaded legs and hand

tighten.

16. Install the washer and large hex flange nut onto the sleeve puller. Turn the large hex flange nut clockwise until the fuel

injector sleeve is removed from cylinder head.



Figure 7: Removal of injector sleeve

Item 1 - ZTSE6095-2 sleeve puller

Item 2 - Injector sleeve


Item 4 - Hand tightened nuts on threaded legs

17. Remove three nuts from the threaded legs. Lift the Tee plate (ZTSE6095-1) from sleeve puller and discard.



Figure 8: Removed injector sleeve


Item 2 - ZTSE6095-2 sleeve puller

Item 3 - Injector sleeve

Item 4 - Injector sleeve O-Rings

INSTALLATION

1. Lubricate the upper O-rings on the new fuel injector sleeve with P-80.

2. Apply Loctite compound 515 to the bottom O-ring

3. Align the hole on side of fuel injector sleeve with hole in cylinder head for high-pressure connector and then place new fuel

injector sleeve into injector port in cylinder head.

4. Place injector sleeve installer assembly (ZTSE6095-5) into fuel injector sleeve. Ensure the spring pin on bottom of the sleeve

installer assembly aligns with groove on fuel injector sleeve. Place sleeve and installer in injector sleeve bore



Figure 9: Spring pin alignment

Item 1 - Spring pin

Item 2 - Injector sleeve groove

5. If not already done, install two threaded legs ZTSE60954 into bolt holes for lost motion pedestal assembly, and one threaded

leg ZTSE6095- 3 into bolt hole for fuel injector clamp bolt.

6. Install Tee plate ZTSE6101-1 onto threaded legs and secure with three nuts hand tight.

There is a "U" shaped cutout on threaded leg ZTSE6095-3 that must be aligned with cup driver

7. Thread forcing screw assembly ZTSE6101-3 into Tee plate ZTSE6101-1 and turn clockwise until injector cup is completely

installed. Injector cup is completely installed when you cannot turn driving bolt anymore. (approx. 24.9 lbft)

8. Unscrew forcing screw assembly ZTSE61013 until it is not in contact with driver and remove the three nuts from the threaded

legs. Lift the Tee plate vertically and remove.

9. Remove threaded legs from cylinder head

10. Remove injector sleeve installer assembly (ZTSE6095-5).



To prevent engine damage, align injector correctly with cylinder head so injector tube inlet port

aligns with pressure pipe holes in cylinder head; do not twist injector when inserting injector into

cylinder head

Figure 10: Fuel Injector

Item 1 Injector

Item 2 - O-ring

Item 3 - Combustion gasket

11. Remove and discard O-ring from each fuel injector

12. Install a new O-ring on each fuel injector. Lubricate O-ring with clean engine oil

13. Install a new combustion gasket on each fuel injector

14. Remove disposable air and fuel caps from cylinder head injector bore

15. Install injector using injector installer ZTSE4777. Push firmly until injector is seated all the way into injector sleeve.

16. Install injector clamp(s), 9.8 x 15.85 x 37.6 spacer(s) and 3/8 16 x 4 hex bolt(s). Tighten 3/8 16 x 4 hex bolt(s) hand tight.



Figure 11: High-pressure connector

Item 1 - High-pressure connector retaining nut (6)

Item 2 - High-pressure connector body (6)

Item 3 - 13 x 3 O-ring (6)

17. Lubricate the 13.5 x 3 O-rings on the high pressure connector bodies with clean engine oil.

18. Install six new high-press connector body and 13.5 x 3 O-ring assemblies.

19. Lubricate the high-pressure connector retaining nut threads with clean engine oil

20. Install high-pressure connector retaining nut(s). Tighten high-pressure connector retaining nut(s) to 55 N·m (40 lbf ·ft)and

then loosen completely. Tighten retaining nut(s) again 10 N·m (88 lbf·in).

21. Tighten 3/8-16 x 4 injector clamp hex bolts to 25 N·m (18 lbf·ft) + 90°.

22. Tighten highpressure connector retaining nuts to 20 N·m (15 lbf·ft) + 25°.

23. Re-install lost motion pedestal(s), rocker arm assembly(s) and valve brake actuator(s) following the service procedures in the

EGES510 service manual

WARRANTY INFORMATION:

Warranty Claim Coding:

Group: 12000 - Engine

Noun: 563 - Injector Unit (Electrical)



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DY46592

You received the following feedback From: dy46592 - Drew Harrison Email Address: [email protected] Job Classification: SE008,

Service Technician Dealer: G & S INDUSTRIAL, INC. Feedback: could you guys include a part number for the high pressure connectors in

the parts break down?

6/29/2015

11:03:21 AM

Copyright © 2015 Navistar, Inc.

STANDARD REPAIR TIMES:

Hours Code Model Engine Qualifier 1

1.7FA12-7563O-2

Injector Sleeves, Replace 9900i |MAXXFORCE 15| Fuel Injector, Replace

Add On

1.7R12-7563O-2

Injector Sleeves, Replace ProStar |MAXXFORCE 15| Fuel Injector, Replace

Add On

1.7T12-7563O-2

Injector Sleeves, Replace 5000 |MAXXFORCE 15| Fuel Injector, Replace

Add On

1.7TC12-7563O-2

Injector Sleeves, Replace CAT CT660 |MAXXFORCE 15| Fuel Injector, Replace

Add On

OTHER RESOURCES:

EPA 2010 MaxxForce 11, 13, N13, and 15 Service Resource Center

MaxxForce® 15L Engine Service Manual (Supersedes EGES-510)

2011 MaxxForce® 15 Engine Diagnostic/Troubleshooting Manual (Revision 1)



maxxforce 15l injector sleeve replacement page 1 of 14fuel injector kit ztse6102 service parts...

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