- Engines:
- 3126B (S/N: 1AJ1-UP; 6PZ1-UP; 7JZ1-UP)
Introduction
The 240-0716 Tube Kit is available for repair of the high pressure oil line. The kit is used in order to replace the flexible high pressure oil line. The oil line is part of the Hydraulic Electronic Unit Injector (HEUI) Pump.
The 240-0716 Tube Kit is used on engine models with the following serial number prefixes: 1AJ, 6PZ and 7JZ.
| Components in 240-0716 Tube Kit | |||
| Callout | Part Number | Description | Quantity |
| 11 | 9M-1974 | Washer | 1 |
| 13 | 122-5855 | Spacer | 1 |
| 10 | 8S-8820 | Clip | 1 |
| 12 | 8C-5748 | Bolt | 1 |
| 9 | 6V-8636 | Connector | 1 |
| 17 | 6V-9001 | Elbow | 1 |
| 15 | 214-7568 | O-ring | 2 |
| 16 | 221-3494 | O-ring | 2 |
| 14 | 241-3782 | Tube assembly | 1 |
| 18 | 033-6028 | O-ring | 1 |
| 19 | 123-3132 | Backup ring | 1 |
| 20 | 033-6039 | O-ring | 1 |
Removal of the Flexible Oil Line
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
| 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. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
- Remove any coolant lines that may interfere with the installation. Remove any air inlet lines that may interfere with the installation.
- Remove bolt (1) and the washer (2) from the air inlet cover (3). Discard the bolt (1) and the washer (2) .
 | |
| Illustration 1 | g01006397 |
Typical example (1) Bolt (2) Washer (3) Air inlet cover | |
- Disconnect the electrical connector of the injection actuation pressure control valve (7). Remove the injection actuation pressure control valve (7) from the pump. Retain the injection actuation pressure control valve (7) for the reinstallation.
- Remove the hose assembly (5), the connector (8), and the elbow (6). Discard these parts.
Note: Modifications to the tools may need to be made in order to reduce interference with engine components.
 | |
| Illustration 2 | g01007381 |
Modified 2P-5494 crowfoot wrench | |
 | |
| Illustration 3 | g01006381 |
(4) HEUI pump (5) Flexible oil line (6) Elbow (7) Injection actuation pressure control valve (8) Connector | |
Installation of the 240-0716 Tube Kit
- Apply a light coat of oil to the O-rings (15) and (16) during installation. Install the O-ring (15) on the connector (9). Install the O-ring (16) on the connector (9). Thread the connector (9) into the port on the cylinder head by hand. Tighten to 48 + 5 N·m (35 + 4 lb ft).
 | |
| Illustration 4 | g01006407 |
(4) HEUI pump (7) Injection actuation pressure control valve (9) Connector (10) Clip (11) Washer (12) Bolt (13) Spacer (14) Tube assembly (15) O-ring (16) O-ring (17) Elbow | |
 | |
| Illustration 5 | g01006437 |
(7) Injection actuation pressure control valve (9) Connector (15) O-ring (16) O-ring (17) Elbow | |
- Apply a light coat of oil to the O-rings (15) and (16) during installation. Install the O-ring (15) on the elbow (17). Install the O-ring (16) on the elbow (17).
- Back off the jam nut on the elbow (17) to the top of the threads on the elbow assembly (17). Push the washer tightly against the jam nut. Check that the washer is as tight as possible. Thread the elbow assembly (17) into the port of the HEUI pump (4). Hand tighten the elbow (17) into the port of the HEUI pump until the washer is tight against the HEUI pump (4). Unscrew the elbow assembly (17) no more than one complete turn to 40 degrees.
- Align the tube assembly (14) with the connector (9) and the elbow (17). Loosely thread each end of the tube assembly (14) onto the connector (9) and the elbow (17). Position the elbow (17) in order to not create stress in the tube assembly (14) .
- Attach the clip (10) to the tube assembly (14). The flat side of the clip (10) must be toward the air inlet cover. Place the washer (11) onto the bolt (12). Insert the bolt (12) through the clip (10) and the spacer (13) .
- Insert the bolt (12) through the air inlet cover (3).
- Thread the bolt (12) into the cylinder head.
- Hand tighten the bolt (12) .
- Hand tighten both connections on the tube assembly (14) .
Note: Ensure that there is no stress on the tube assembly (14) from any components or fittings.
- Use a wrench to prevent the elbow assembly (17) from turning. Tighten the bottom tube fitting to the elbow assembly (17) to 40 + 4 N·m (29.5 + 3 lb ft).
- Tighten the top tube fitting to the connector (9) to 40 + 4 N·m (29.5 + 3 lb ft).
- Use a wrench to prevent the elbow assembly (17) from turning. Tighten the jam nut of the elbow assembly (17) to 24 + 2 N·m (18 + 1.5 lb ft).
- Tighten the bolt (12) to 28 ± 7 N·m (21 ± 5 lb ft).
- Remove the existing components from the injection actuation pressure control valve (7). Discard the existing components. Install the new components for the injection actuation pressure control valve on the injection actuation pressure control valve (7). Apply a light coat of oil on the new components during installation. Install the injection actuation pressure control valve (7) into the port on the HEUI pump (4). Tighten the injection actuation pressure control valve (7) to 50 ± 5 N·m (37 ± 3.7 lb ft).
 | |
| Illustration 6 | g01006732 |
(7) Injection actuation pressure control valve (18) O-ring (19) Backup ring (20) O-ring | |
Note: Note the location of the components on the injection actuation pressure control valve prior to replacement.
- Reconnect the wiring to the injection actuation pressure control valve (7) .
- Inspect any coolant lines or any air inlet lines that were disconnected. Reinstall any coolant lines or any air inlet lines that were disconnected. If necessary, repair the lines or replace the lines.
- Check all fluid levels. Fill all fluids to the proper level.
- Clean up any fluids from the assembly process. Run the engine in order to check for leaks. Repair any fittings that may be leaking.