C6.6 Industrial Engine Electronic Control Module - Remove and Install - Electronic Control Module With Banjo Bolt Connections Caterpillar

Removal Procedure

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

2. Turn the fuel supply to the OFF position.
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   Illustration 1	g02163193
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3. Cut all cable straps that attach the wiring harness assemblies to electronic control module (6).

   Note: Note position of cable straps that attach the wiring harness assemblies to the electronic control module.

4. Remove bolt (2). Loosen Allen head bolts (3) that secures engine wiring harness assembly (4) to electronic control module (6). Disconnect the engine wiring harness assembly from the electronic control module.

5. Remove bolt (7). Loosen Allen head bolts (5) that secures engine wiring harness assembly (9) to electronic control module (6). Disconnect the Original Equipment Manufactures (OEM) wiring harness assembly from the electronic control module.

6. Position harness assembly (9) and harness assembly (4) away from electronic control module (6).

7. Make temporary identification marks on fuel line (1) and fuel line (8) in order to show the correct position of the fuel lines.

8. Place a suitable container below electronic control module (6) in order to catch any fuel that might be spilled.
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   Illustration 2	g02163197
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9. Loosen banjo bolt (10) and banjo bolt (13) in order to drain the fuel from the electronic control module.

10. Remove banjo bolt (10) from fuel line (1). Remove sealing washers (11) from banjo bolt (10).

11. Remove fuel line (1) from fuel line clips. Position the fuel line away from the electronic control module.

12. Use Tooling (A) to cap fuel line (1) and plug the connection on the electronic control module.

13. Remove banjo bolt (13) from fuel line (8). Remove sealing washers (12) from banjo bolt (13).

14. Use Tooling (A) to cap fuel line (8) and plug the connection on the electronic control module.
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    Illustration 3	g02163198
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    Illustration 4	g02163199
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15. Loosen bolts (18) for electronic control module (6).

16. Remove bolts (18) and remove washers (16) and washer (17). Take care to prevent damage to ground connection (14).

    Note: Support the weight of the electronic control module as the remaining bolts are removed.

17. Remove bracket (13) and remove electronic control module (6) from mounting bracket for the electronic control module.

    Note: Note the orientation of the electronic control module.

18. If necessary, follow Step 18.a through Step 18.c in order to disassemble the electronic control module.

    1. Remove connection (21) and O-ring seal (22). Use Tooling (A) to plug the electronic control module and cap the connection.

    2. Remove connection (24) and O-ring seal (23) (not shown). Use Tooling (A) to plug the electronic control module and cap the connection.

    3. Remove isolation mounts (15), isolation mounts (19), and limit sleeves (20) from electronic control module (6).

Installation Procedure

1. If a replacement electronic control module is installed, the module must be programmed with the correct information. Refer to Troubleshooting , "Replacing the ECM" and refer to Troubleshooting , "Flash Programming" for the correct procedure.

2. Ensure that the electronic control module is clean and free from damage. If necessary, replace the electronic control module.
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   Illustration 5	g02163199
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3. If necessary, follow Step 3.a through Step 3.d in order to assemble electronic control module (6).

   1. Remove the cap from connection (21). Install a new O-ring seal (22) to the connection.

   2. Remove the cap from connection (24). Install a new O-ring seal (23) (not shown) to the connection.

   3. Remove the plugs from electronic control module (6).

   4. Install connector (21) and connector (24) to electronic control module (6). Tighten the connections to a torque of 18 N·m (159 lb in).
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   Illustration 6	g02163198
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   Illustration 7	g02163646
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4. Install isolation mounts (15), isolation mounts (19), and limit sleeves (20) to electronic control module (6).

5. Install washers (16) and washer (17) to bolts (18) to the lower isolation mounts.

   Note: Ensure that ground strap (14) for the electronic control module is clamped between washer (16) and washer (17).

6. Position electronic control module (6) on mounting bracket (25) for the electronic control module. Loosely install bolts (18).

   Note: Ensure that the electronic control module is correctly oriented.

7. Position bracket (13) onto electronic control module (6). Install remaining bolts (18) to bracket (13).

8. Tighten bolts (18) to a torque of 22 N·m (195 lb in).

   Note: Ensure that the ground strap is not strained as the bolt is tightened.

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   Illustration 8	g02163660
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9. Install a new sealing washer (12) to banjo bolt (13).

10. Remove the plug from fuel line (8) and remove the plug from connection (24) on the electronic control module.

11. Install banjo bolt (13) to fuel line (8) and install remaining new washer (12) to banjo bolt (13). Position fuel line assembly (8) onto connection (24) and hand tighten banjo bolt.

12. Tighten banjo bolt (13) to a torque of 18 N·m (159 lb in).

    Note: Ensure that the fuel line is not strained as the banjo bolt is tightened.

13. Install a new sealing washer (11) to banjo bolt (10).

14. Remove the plug from fuel line (1) and remove the plug from connection (21) on the electronic control module.

15. Install banjo bolt (10) to fuel line (1) and install remaining new washer (11) to banjo bolt (10). Position fuel line assembly (1) onto connection (21) and hand tighten banjo bolt.

16. Install fuel line (1) to fuel line clips.

17. Tighten banjo bolt (10) to a torque of 18 N·m (159 lb in).

    Note: Ensure that the fuel line is not strained as the banjo bolt is tightened.

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    Illustration 9	g02163193
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18. Connect engine wiring harness assembly (4) to electronic control module (6). Tighten Allen head bolt (3) to a torque of 6 N·m (53 lb in).

    Note: Care must be taken in order to avoid damage to the connector pins during installation of the wiring harness assembly.

19. Install bolt (2) and tighten the bolt to a torque of 6.5 N·m (58 lb in).

20. Connect OEM wiring harness assembly (9) to electronic control module (6). Tighten Allen head bolt (5) to a torque of 6 N·m (53 lb in).

    Note: Care must be taken in order to avoid damage to the connector pins during installation of the harness assembly.

21. Install bolt (7) and tighten the bolt to a torque of 6.5 N·m (58 lb in).

22. Install new cable straps to the wiring harness assemblies.

    Note: Ensure that the cable straps meet the Original Equipment Manufactures (OEM) specifications.

23. Turn the fuel supply to the ON position.

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

25. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.