C9 On-highway Engine Caterpillar

Installation Procedure

1. Evacuate as much fuel and oil as possible from the cylinder head before installing the unit injector. Several evacuations may be necessary. Use Tooling (C) to remove the fuel and oil from the cylinder.

   Note: Tooling (F) is available to clean loose material from the sleeve bore and the cylinder.

2. Clean the carbon from the sleeve, the sleeve bore and the end of the unit injector. Clean the carbon from the seat area that is inside of the cylinder head. A fine grade of Tooling (B) is preferred. Clean the carbon from the cylinder head. If the sleeve of the unit injector has been removed from the engine, use Tooling (D) to remove only carbon from the surface of the sleeve. If the sleeve of the unit injector is installed in the engine, use Tooling (E) to clean the carbon deposit from the inside of the sleeve.

   The following procedure is the preferred method of cleaning the sleeve bore.

   Place a 38 mm (1.5 inch) square piece of Scotch Brite material on the end of Tooling (F) . Twist Tooling (F) with Tooling (H) against the lower surface of the sleeve bore.

   The surface should be cleaned until the surface is smooth and shiny. The entire sleeve bore should be cleaned in order to remove any loose carbon particles.

   Note: Tooling (G) is available to clean loose material from the sleeve bore and the cylinder.

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NOTICE
The correct procedures and tooling specifications must always be used. Failure to follow any of the procedures may result in damage, malfunction, or possible engine failure.

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Illustration 1	g01355602

Note: Replace the O-ring seals on the injector.

3. Install O-ring seal (9) and O-ring seal (10) on unit injector (4) . Lubricate O-ring seal (9) , O-ring seal (10) , and the sleeve bore of the unit injector sparingly with clean engine oil.

4. Record the serial number for the injector and the injector confirmation code. When you install a new unit injector the E-Trim value must be programmed into the Engine Control Module. For more information, refer to Troubleshooting, "Injector Code - Calibrate".

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Illustration 2	g01355632

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Illustration 3	g01264293

Note: Verify quill tube (1) is positioned out of the bore enough to see O-ring seal (2) . This will ensure that the injector does not contact the quill tube during installation.

5. Place unit injector (4) into the bore. Make sure that the key (11) for the unit injector fits into slot (12) in the cylinder head.

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Illustration 4	g01354952

Note: Use new socket head bolt (7) .

6. Position unit injector clamp (8) with the label "C9" in the up position. Install socket head bolt (7) into unit injector clamp (8) . Tighten socket head bolt (7) to a torque of 28 ± 3 N·m (21 ± 2 lb ft).

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Illustration 5	g01356104

7. Position harness assembly (5) and install nuts (6) .

8. Connect harness assembly (3) to unit injector (4) .

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Illustration 6	g01355441

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Illustration 7	g01355608

Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal.

9. If the O-ring was damaged, perform Step 9.a and Step 9.b.
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   Illustration 8	g02077582

   1. Inspect the sealing surface (A) for damage. Replace quill tube (1) if damage was found.

   2. Lubricate new O-ring seal (2) with clean engine oil. Install new O-ring (2) .

10. Lubricate the O-ring seal, the nut face and the threads with clean engine oil. Insert quill tube (1) into the bore with the ball on the right side. Once the quill tube has bottomed out, rotate the quill tube until the ball engages with the slot. The quill tube should drop slightly when the ball is engaged with the slot. This will install quill tube (1) . Ensure that the ball is in alignment with the slot for quill tube (1) . Tighten the nut for quill tube (1) to a torque of 70 ± 3 N·m (52 ± 2 lb ft).

End By:

1. Install the fuel injection line. Refer to Disassembly and Assembly, "Fuel Lines - Remove and Install".
2. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".