Removal Procedure
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 5F-4764 | Pry Bar | 1 |
Start By:
- Remove the rocker shafts. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove".
- Disconnect hose assemblies (1) .
| 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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. |
 | |
| Illustration 1 | g01009601 |
- Drain the fuel from the cylinder head.
- Disconnect harness assembly (2) from unit injector (3) .
 | |
| Illustration 2 | g01261606 |
- Remove bolt (4) .
- Position Tooling (A) under bracket (5) in order to remove unit injector (3) .
 | |
| Illustration 3 | g01261609 |
Installation Procedure
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| B | 9U-6862 | Tapered Brush | 1 |
| 9U-7237 | Brush Extension | 1 | |
| C | 9U-6863 | Small Bore Brush | 1 |
| 9U-7237 | Brush Extension | 1 | |
| D | 8T-2998 | Lubricant | 1 |
| E | 1U-5718 | Vacuum Pump | 1 |
| 169-7372 | Fluid Sampling Bottle | - | |
| 4C-4057 | Tube 7.9 mm (0.31 inch) OD |
- | |
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Use Tooling (E) to remove the fuel and oil from the cylinder. Evacuate as much fuel and oil as possible from the cylinder before installing the electronic unit injector. Several evacuations may be necessary.
- Use Tooling (B) to clean injector seating (7) .
 | |
| Illustration 4 | g01009642 |
(7) Injector seating (8) Tip bore | |
- Use Tooling (C) to clean tip bore (8) .
Note: Do not reuse seals. Use new seals for installation.
- Lubricate the bore lightly with a 50/50 mix of clean engine oil and Tooling (D) .
Note: The injector code will be used later if the injectors have been changed. Write down the injector code which is located on the side of the solenoid, on top of the solenoid, or on top of the injector tappet.
| | |
| Illustration 5 | g01261606 |
- Install unit injector (3) and bracket (5) .
 | |
| Illustration 6 | g01009643 |
(Y) Electronic injector code | |
| NOTICE |
|---|
When a fuel injector group is serviced, the new fuel injector group's electronic injector code must be programmed into the engine's personality module software by using the calibration menu on the Electronic Service Tool. If the new fuel injector group's electronic code is not entered, the previous fuel injector group's characteristics are assumed. If it is not possible to immediately reprogram the electronic injector code of the injector into the personality module software, the engine will not be severely harmed. The new electronic injector code should be reprogrammed as quickly as possible in order to optimize engine performance. |
- Install bolt (4) . Tighten bolt (4) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
- Connect harness assembly (2) to unit injector (3) .
- Connect hose assemblies (1) .
| | |
| Illustration 7 | g01009601 |
End By: Install the rocker shafts. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install".