Electronic Unit Injector - Install: C6.6 Industrial Engine

Service Information System Page 1 of 13
Disassembly and Assembly

C6.6 Industrial Engine
Media Number -RENR9722-01 Publication Date -2007/10/01 Date Updated -2007/10/10
i02863372
Electronic Unit Injector - Install

SMCS - 1290-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
B 298-5564 T40 Torx Socket 1
1U-5718 Vacuum Pump 1
169-7372 Fluid Sampling Bottle 1
D
Tube
4C-4057 1
7.9 mm (0.31 inch) Outside Diameter
E 276-1216 Injector Pipe Nut Tool 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.
https://sisweb.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/sisweb/sisweb/tec... 25/08/2008
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 remove the electrical connections from
the electronic unit injectors. Use of incorrect tooling will result in
damage to the electronic unit injectors.
View Image
Illustration 1 g01341874
Typical calibration code
1. If a replacement electronic unit injector is installed, the correct injector trim file must be
programmed into the electronic control module. Refer to Troubleshooting, "Injector Trim File" for
more information. The code that is required to obtain the injector trim file is located at position
(X) .
Note: Record code (X) before the electronic unit injector is installed.
2. 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.
3. Ensure that the fuel inlet port of the electronic unit injector is capped. Ensure that the electronic
unit injector is clean.
View Image
4. On installing an original electronic unit injector, install a new O-ring seal (15) and sealing washer
(14) to electronic unit injector (11) .
Ensure that the O-ring seal (15) and sealing washer (14) on a new electronic unit injector are not
damaged and in place.
Note: Do not lubricate the O-ring seal.
5. 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.
View Image
The rocker shaft is not shown for clarity.
6. Position clamp (13) between the rocker arm and the valve springs. Align electronic unit injector
(11) to the bore for the electronic unit injector in the cylinder head. Install the clamp to the
electronic unit injector. Ensure that the electronic unit injector is pushed firmly against the seat in
the cylinder head.
7. Install a new torx screw (12) to clamp (13). Tighten the torx screw finger tight.
8. Remove the cap from electronic unit injector (11). Install a new seal (8) to electronic unit injector
(11) and to the valve mechanism cover base. Ensure that the flange on the seal is flush with the
valve mechanism cover base.
9. Remove the plugs from the new fuel injection line. Loosely install the fuel injection line. Refer to
Disassembly and Assembly, "Fuel Injecton Lines - Install".
Note: Ensure that the ends of the fuel injection line are seated in the electronic unit injector and
the fuel manifold. Tighten the nuts finger tight.
10. Use Tooling (B) to tighten torx screw (12) to a torque of 27 N·m (20 lb ft).
Note: Tooling (B) must be used to ensure no damage to the rocker arms.
11. Use Tooling (E) to tighten the fuel injection line to a torque of 30 N·m (22 lb ft). Refer to
View Image
Typical example
12. Install valve bridges (5) (not shown) 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.
View Image
The correct location of valve bridges on valve stems is shown. The electronic unit injector is not shown for clarity.
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.
13. Ensure that the bottoms of the pushrods are seated in the cups of the valve lifters. Locate the balls
of adjusters (2) into the cups of pushrods (4) .
14. Adjust the valve lash. Refer to Systems Operation, Testing and Adjusting, "Engine Valve Lash -
Inspect/Adjust".
15. Use a deep socket to install harness assembly (9) to electronic unit injector (11). Use Tooling (F)
to tighten connections (10) to a torque of 2.4 N·m (21 lb in).
View Image
Typical example
16. Tighten banjo bolt (7) for tube assembly (6). Tighten the banjo bolt to a torque of 21 N·m (15 lb
ft).
17. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Remove and Install".
18. Turn the fuel supply to the ON position.
19. Turn the battery disconnect switch to the ON position.
20. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System -
Prime" for more information.
Alternative Installation Procedure

Table 2
Required Tools
Tool Part Number Part Description Qty
B 298-5564 T40 Torx Socket 1
1U-5718 Vacuum Pump 1
D 169-7372 Fluid Sampling Bottle 1
Tube
4C-4057 1
7.9 mm (0.31 inch) OD
E 276-1216 Injector Pipe Nut Tool 1
F 247-5377 Torque Wrench 1
Note: This is an optional procedure to install the electronic unit injectors. The method should ONLY be
used when all electronic unit injectors are installed and when the engine is removed from the
application.
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 remove the electrical connections from
the electronic unit injectors. Use of incorrect tooling will result in
damage to the electronic unit injectors.
View Image
Typical calibration code
1. If a replacement electronic unit injector is installed, the correct injector trim file must be
programmed into the electronic control module. Refer to Troubleshooting, "Injector Trim File" for
more information. The code that is required to obtain the injector trim file is located at position
(X) .
Note: Record code (X) before the electronic unit injector is installed.
2. Use Tooling (D) to remove any fuel from the cylinder.
Note: Evacuate as much fuel as possible from the cylinder before installing the electronic unit
injector.
3. Ensure that the fuel inlet port of the electronic unit injector is capped. Ensure that the electronic
unit injector is clean.
View Image
4. On installing an original electronic unit injector, install a new O-ring seal (15) and sealing washer
(14) to electronic unit injector (11) .
Ensure that the O-ring seal (15) and sealing washer (14) on a new electronic unit injector are not
damaged and in place.
Note: Do not lubricate the O-ring seal.
5. 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.
View Image
6. Install clamp (13) to electronic unit injector (11). Install the electronic unit injector assembly into
the original location in the cylinder head.
Note: Ensure that the electronic unit injector is pushed firmly against the seat in the cylinder head.
Install the electronic unit injector for number one cylinder first. Install the electronic unit injectors
in numerical order.
7. Install a new torx screw (12) to clamp (13). Tighten the torx screw finger tight.
8. Remove the cap from electronic unit injector (11). Install a new seal (8) to electronic unit injector
(11) and to the valve mechanism cover base. Ensure that the flange on the seal is flush with the
valve mechanism cover base.
9. Remove the plugs from the new fuel injection line. Loosely install the fuel injection line. Refer to
Note: Ensure that the ends of the fuel injection line are seated in the electronic unit injector and
the fuel manifold. Tighten the nuts finger tight.
10. Use Tooling (B) to tighten torx screw (12) to a torque of 27 N·m (20 lb ft).
11. Use Tooling (E) to tighten the fuel injection line to a torque of 30 N·m (22 lb ft). Refer to
12. Repeat Steps 2 through 11 in order to install the remaining electronic unit injectors.
13. Use a deep socket to install harness assemblies (9) to electronic unit injectors (11). Use Tooling
(F) to tighten connections (10) to a torque of 2.4 N·m (21 lb in).
View Image
The correct location of valve bridges on valve stems is shown. The electronic unit injector is not shown for clarity.
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.
14. Install the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft - Install".
View Image
Typical example
15. Tighten banjo bolt (7) for tube assembly (6). Tighten the banjo bolt to a torque of 21 N·m (15 lb
ft).
16. Turn the fuel supply to the ON position.
17. Turn the battery disconnect switch to the ON position.
18. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System -
Prime" for more information.
Copyright 1993 - 2008 Caterpillar Inc. Mon Aug 25 16:55:03 UTC+0100 2008
All Rights Reserved.
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Service Information System Page 1 of 13

Disassembly and Assembly

Electronic Unit Injector - Install

Refer to Systems Operation, Testing and Adjusting Manual,

Dispose of all fluids according to local regulations and mandates.

Note: Do not lubricate the O-ring seal.

18. Turn the fuel supply to the ON position.

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

Alternative Installation Procedure

Refer to Systems Operation, Testing and Adjusting Manual,

Dispose of all fluids according to local regulations and mandates.

2. Use Tooling (D) to remove any fuel from the cylinder.

Note: Do not lubricate the O-ring seal.

16. Turn the fuel supply to the ON position.

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

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