Installation Instructions for the 240-0717 Engine Oil Lines Gp for the Hydraulic Electronic Unit Injector (HEUI) Pump{1307} Caterpillar

Truck Engines:

3126B (S/N: BKD1-UP; 1AJ1-UP; 5GL1-UP; 8YL1-UP; 7AS1-UP; 8SZ1-UP)

3126E (S/N: DPF1-UP; 6ZG1-UP; CKM1-UP; CRP1-UP; 9SZ1-UP)

Introduction

The 240-0717 Engine Oil Lines Gp 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 Pump.

Note: This kit includes two different spacers. 122-5855 Spacer has an outer diameter of 20 mm (0.79 inch) and a length of 26 mm (1.02 inch). 135-5096 Spacer has an outer diameter of 17 mm (0.67 inch) and a length of 16 mm (0.63 inch). Make sure that the correct spacer is used. Failure to use the correct mounting hardware and the correct installation procedure may result in failure of the Engine Oil Lines Gp.

The 240-0717 Engine Oil Lines Gp is used on engine models with the following serial number prefixes (S/N: 1AJ; 5GL; 6ZG; 7AS; 8YL; 8SZ; 9SZ; BKD; CKM; CRP; DPF).

Note: Engines that are equipped with a remotely mounted fuel filter base must use 122-5855 Spacer . A remotely mounted fuel filter base allows the oil lines and the spacer to be directly bolted to the inlet manifold cover. Refer to illustration 2. Discard the 135-5096 Spacer .

Note: Engines that use the middle mounted fuel filter bracket must use 135-5096 Spacer for the installation of the kit. Refer to illustration 1. Discard the 122-5855 Spacer .

Removal of the Flexible Oil Line

1. Remove any coolant lines that may interfere with the installation. Remove any air inlet lines that may interfere with the installation.

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Illustration 1	g01043884
Air inlet cover with the middle mounted fuel filter bracket (1) Bolt (2) Washer (3) Air inlet cover (4) 163-8702 Bracket for mounting the fuel filter

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Illustration 2	g01043885
The air inlet cover without the fuel filter mounting bracket is found on engines that have a remotely mounted fuel filter base. (1) Bolt (2) Washer (3) Air inlet cover

2. Remove bolt (1) and the washer (2) from the air inlet cover (3). Discard the bolt (1) and the washer (2) .

3. Disconnect the electrical connector of the injection actuation pressure control valve (8). Remove the injection actuation pressure control valve (8) from the pump. Retain the injection actuation pressure control valve (8) for the reinstallation.

Note: Modifications to the tools may need to be made in order to reduce interference with engine components.

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Illustration 3	g01007381
Modified 2P-5494 crowfoot wrench

4. Remove the hose assembly (6) and the two connectors (7). Discard these parts.

Illustration 4	g01043882
(5) HEUI pump (6) Flexible oil line (7) Connector (8) Injection actuation pressure control valve

Installation of the 240-0717 Engine Oil Lines Gp

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Illustration 5	g01043862
(5) HEUI pump (8) 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

Note: Some engines may not have a fuel filter mounting bracket. The existence of the fuel filter mounting bracket on the air inlet cover helps to determine the proper spacer to use. If the fuel filter bracket is mounted on the air inlet cover then the 135-5096 Spacer must be used. If the fuel filter bracket is not mounted on the air inlet cover then the 122-5855 Spacer must be used.

Note: In order to determine the correct spacer for installation, refer to the original assembly. Refer to illustration 1 and illustration 2. Refer to illustration 6 and illustration 7 for the correct installation of the spacer and clip.

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Illustration 6	g01043888
Correct installation of 122-5855 Spacer with no fuel filter mounting bracket (10) Clip (11) Washer (12) Bolt (13) Spacer (14) Tube assembly

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Illustration 7	g01045006
Correct installation of 135-5096 Spacer with the fuel filter mounting bracket (10) Clip (11) Washer (12) Bolt (13) Spacer (14) Tube assembly

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Illustration 8	g01043711
(8) Injection actuation pressure control valve (9) Connector (15) O-ring (16) O-ring (17) Elbow

1. 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).

2. 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).

3. 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 (5). Hand tighten the elbow (17) into the port of the HEUI pump until the washer is tight against the HEUI pump (5). Unscrew the elbow assembly (17) no more than one complete turn to 40 degrees.

4. 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) .

5. 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) .

   Note: This kit includes two different spacers. 122-5855 Spacer has an outer diameter of 20 mm (0.79 inch) and a length of 26 mm (1.02 inch). 135-5096 Spacer has an outer diameter of 17 mm (0.67 inch) and a length of 16 mm (0.63 inch). Make sure that the correct spacer is used. Failure to use the correct mounting hardware and the correct installation procedure may result in failure of the Engine Oil Lines Gp.

6. Insert the bolt (12) through the air inlet cover (3).

7. Thread the bolt (12) into the cylinder head.

8. Hand tighten the bolt (12) .

9. 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.

10. 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).

11. Use a wrench in order to prevent the connector (9) from turning. Tighten the top tube fitting to the connector (9) to 40 + 4 N·m (29.5 + 3 lb ft).

12. Use a wrench to prevent the elbow assembly (17) from turning. Tighten the jam nut of the elbow assembly (17) to the HEUI pump to 24 + 2 N·m (18 + 1.5 lb ft).

13. Tighten the bolt (12) to 28 ± 7 N·m (21 ± 5 lb ft).

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Illustration 9	g01043714
(8) 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.

14. Remove the existing components from the injection actuation pressure control valve (8). Discard the existing components. Install the new components for the injection actuation pressure control valve on the injection actuation pressure control valve (8). Apply a light coat of oil on the new components during installation. Install the injection actuation pressure control valve (8) into the port on the HEUI pump (5). Tighten the injection actuation pressure control valve (8) to 50 ± 5 N·m (37 ± 3.7 lb ft).

15. Reconnect the wiring to the injection actuation pressure control valve (8) .

16. 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.

17. Check all fluid levels. Fill all fluids to the proper level.

18. Clean up any fluids from the assembly process. Run the engine in order to check for leaks. Repair any fittings that may be leaking.