C6.6 Industrial Engine Electronic Unit Injector - Install Caterpillar


Electronic Unit Injector - Install
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1.1. Installation Procedure

Installation Procedure

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     298-5564     T40 Torx Socket     1    
D     1U-5718     Vacuum Pump     1    
169-7372 Fluid Sampling Bottle     1    
4C-4057 Tube
7.9 mm (0.31 inch) Outside Diameter    
1    
E     276-1216     Crows Foot Wrench     1    
F     247-5377     Torque Wrench     1    


NOTICE

Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training.

Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information.

Refer to Systems Operation, Testing and Adjusting Manual, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.



NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Dispose of all fluids according to local regulations and mandates.



NOTICE

Use a deep socket in order to install the electrical connections to the electronic unit injectors. Use of incorrect tooling will result in damage to the electronic unit injectors.





    Illustration 1g02353356

    Injector code

  1. If the original electronic unit injector (8) is installed, ensure that the electronic unit injector is installed into the original position.

  1. If a replacement electronic unit injector is installed, the correct injector code must be programmed into the electronic control module. Refer to Troubleshooting, "Injector Code - Calibrate" for more information. The code that is required is located at Position (X) .

    Note: Record Code (X) before the electronic unit injector is installed.

  1. Use Tooling (D) in order to remove any fuel from the cylinder.

    Note: Evacuate as much fuel as possible from the cylinder before installing the electronic unit injector.




    Illustration 2g02313273

  1. If necessary, follow Step 4.a through Step 4.e in order to install new harness assemblies (6) to cylinder head (16) .

    1. Install a new harness assembly (6) to cylinder head (16) .

    1. Install a new bolt (14) to harness assembly (6) . Tighten the bolt to a torque of 5.5 N·m (49 lb in).

    1. Install new assemblies of cable strap (13) for harness assembly (6) to cylinder head (16) .

      Note: Ensure that the assemblies of the cable strap are correctly installed into the cylinder head.

    1. Connect harness assembly (15) to harness assembly (6) .

    1. If necessary, repeat Step 4.a through Step 4.e in order to install the remaining harness assemblies to the cylinder head.

  1. Ensure that the fuel inlet port of the electronic unit injector is capped. Ensure that the electronic unit injector is clean.



    Illustration 3g01972153

  1. New sealing washer (12) should only be installed if the original electronic unit injector (8) is to be reused.

  1. On installing an original electronic unit injector, install a new O-ring seal (11) .

    Note: Do not lubricate the O-ring seal.

  1. Use a suitable tool in order to install a new sealing washer (12) to electronic unit injector (8) .

    Note: Ensure that the nozzle for the electronic unit injector is not damaged in any way on installation of the new sealing washer.

  1. Ensure that O-ring seal (11) and sealing washer (12) on a new electronic unit injector are not damaged and in place.

    Note: Do not lubricate the O-ring seal.

  1. Ensure that the seat for the electronic unit injector in the cylinder head is clean and free from damage. Ensure that the sealing washer has been removed from the cylinder head.



    Illustration 4g01971773

  1. Position clamp (10) onto electronic unit injector (8) . Align the assembly of electronic unit injector (8) to the bore for the electronic unit injector in the cylinder head.

    Note: Ensure that the clamp is correctly positioned onto the electronic unit injector.

  1. Push only on injector clamp (10) in order to install electronic unit injector (8) . Do not apply pressure on any other part of the electronic unit injector. Ensure that the electronic unit injector is pushed firmly against the seat in the cylinder head.

  1. Install a new Torx screw (9) to clamp (10) . Tighten the Torx screw finger tight.

  1. Remove the cap from electronic unit injector (8) . Install a new seal (4) to electronic unit injector (8) and to the cylinder head. Ensure that the flange on the seal is flush with the cylinder head.

  1. Remove the plugs from the new fuel injection line. Install the fuel injection line hand tight. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.

    Note: Ensure that the ends of the fuel injection line are seated into the electronic unit injector and the fuel manifold. Tighten the nuts hand tight.

  1. Use Tooling (A) to tighten Torx screw (9) to a torque of 27 N·m (239 lb in).

    Note: Tooling (A) must be used to ensure no damage to the electronic unit injector.

  1. Use Tooling (E) to tighten the fuel injection line to a torque of 50 N·m (37 lb ft). Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.

  1. Use a deep socket to install harness assembly (6) to electronic unit injector (8) . Use Tooling (F) to tighten connections (7) to a torque of 2.0 N·m (18 lb in).

  1. If necessary, repeat Step 1 through Step 18 in order to install the remaining electronic unit injectors.



    Illustration 5g01973093

    The correct location of valve bridges


    NOTICE

    Failure to ensure that ALL valve bridges are correctly seated onto the valve stems will cause interference between the pistons and the valves, resulting in damage to the engine.


  1. Install valve bridges (5) to the cylinder head.

    Note: Ensure that used valve bridges are reinstalled in the original location and the original orientation. Do not interchange the location or the orientation of used valve bridges.

  1. Install the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft - Install" for the correct procedure.



    Illustration 6g01971774

  1. Install a new O-ring seal (2) to the connection on tube assembly (1) .

  1. Install hose assembly (3) to tube assembly (1) . Tighten the nut on hose assembly (3) to a torque of 21 N·m (186 lb in).

  1. Replace the filters for primary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element - Replace" for the correct procedure.

  1. Replace the filters for secondary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.

  1. Turn the fuel supply to the ON position.

  1. Turn the battery disconnect switch to the ON position.

  1. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for more information.

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