C7.1 Engines for Caterpillar Built Machines Caterpillar

Removal Procedure

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Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately.

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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

1. Turn the fuel supply to the OFF position.

2. Turn the battery disconnect switch to the OFF position.

3. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure.
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   Illustration 1	g02158579

4. Remove allen head bolts (5) (not shown) from tube assembly clamps (6).

5. Disconnected fuel tube assembly (11) from ARD combustion head (9). Plug the tube assembly with new plugs. Cap all open connectors on the combustion head with new caps.

6. Disconnected tube assembly (2) and tube assembly (3) from ARD combustion head (9). Plug the tube assemblies with new plugs. Cap all open connectors on the combustion head with new caps.

7. Remove bolt (4) from the ground strap and disconnect ignition wire (1) from the spark plug.

8. Remove allen head screw (10) and remove clamp from the ARD combustion head (9). Remove heated nozzle connection (13) from the ARD combustion head.

9. Remove flame detection temperature sensor (12) from ARD combustion head (9). Refer to Disassembly and Assembly, "Flame Detection Temperature Sensor - Remove and Install" for the correct procedure.

10. Remove allen head bolts (7) and remove gasket (8) (not shown).
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    Illustration 2	g02158581

11. Remove spark plug (15) from ARD combustion head (9). Refer to Disassembly and Assembly, "ARD Spark Plug - Remove and Install" for the correct procedure.

12. Loosen nuts (15) in a crisscross pattern. Remove nuts (15) from ARD combustion head (9).
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    Illustration 3	g02158582

13. Remove ARD combustion head (9).

14. Remove gasket (18). Remove combustion tube assembly (17) and remove gasket (16).
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    Illustration 4	g02158584

15. If necessary, follow Step 15.a through Step 15.b to remove fuel connection and the connections for the coolant from the ARD combustion head.

    1. Remove fuel connection (24) from ARD combustion head (9).

    2. Remove O-ring seal (23) from connection (24).

    3. Remove coolant connection (19) and coolant connection (21) from ARD combustion head (9).

    4. Remove O-ring seal (20) (not shown) from coolant connection (19).

    5. Remove O-ring seal (22) (not shown) from coolant connection (21).
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    Illustration 5	g02158585

16. If necessary, remove studs (26) from body (25) of the ARD.

Installation Procedure

1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
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   Illustration 6	g02158585

2. If necessary, install studs (26) to ARD body (25). Apply Tooling (A) onto the threads of studs (26). Install the studs to body (25) of the ARD.

   Tighten studs (26) to a torque of 17 N·m (150 lb in).

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   Illustration 7	g02158584

3. If necessary, follow Step 3.a through Step 3.d to install the fuel connection and the connections for the coolant to the ARD combustion head.

   1. Ensure that the filter in fuel connection (24) is clean and free from damage. Ensure that the filter in the combustion head (9) is clean and free from damage.

   2. Install a new O-ring seal (23) to fuel connection (24). Install the connection to ARD combustion head (9). Tighten the connection to a torque of 60 N·m (44 lb ft).

   3. Install a new O-ring seal (20) (not shown) to coolant connection (19). Install coolant connection (19) to ARD combustion head (9). Tighten the connections to a torque of 30 N·m (266 lb in).

   4. Install a new O-ring seal (22) (not shown) to coolant connection (21). Install coolant connection (21) to ARD combustion head (9). Tighten the connections to a torque of 30 N·m (266 lb in).
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   Illustration 8	g02158582

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   Illustration 9	g02158581

4. Thoroughly clean the gasket surfaces of the ARD combustion head, combustion tube assembly, and the ARD body. Do not damage the gasket surfaces of the combustion head of the ARD body. Ensure that no debris enters the assembly of the clean emission module.

5. Install a new gasket (16) and install combustion tube assembly (17). Install a new gasket (18).

6. Install ARD combustion head (9).

7. Apply Tooling (A) onto the threads of the studs and nuts (15). Install nuts (15) to ARD combustion head (9).

8. Tighten nuts (15) in a crisscross pattern to a torque of 23 N·m (204 lb in). Tighten nuts (15) again in a crisscross pattern to a torque of 28 N·m (248 lb in). Tighten nuts (15) again in a crisscross pattern to a torque of 28 N·m (248 lb in).

9. Install spark plug (14) to ARD combustion head (9). Tighten spark plug (14) to a torque of 57.5 ± 4 N·m (42 ± 3 lb ft). Refer to Disassembly and Assembly, "ARD Spark Plug - Remove and Install" for the correct procedure.
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   Illustration 10	g02158579

10. Install a new gasket (8) (not shown). Install allen head bolt (7). Tighten allen head bolts (7) to a torque of 28 N·m (248 lb in).

11. Apply Tooling (B) to the thread of flame detection temperature sensor (12). Install flame detection temperature sensor (12) to the ARD combustion head. Tighten flame detection temperature sensors (12) to a torque of 45 N·m (33 lb ft). Refer to Disassembly and Assembly, "Flame Detection Temperature Sensor - Remove and Install" for the correct procedure.

12. Install heated nozzle connection (13) to the ARD combustion head. Install allen head bolt (10).

13. Use Tooling (C) to tighten the allen head bolt to a torque of 1.7 N·m (15 lb in).

14. Connect ignition wire (1) to the spark plug. Install bolt (4) to the ground strap. Tighten bolt (4) to a torque of 12 N·m (106 lb in).

15. Remove the plug from fuel tube assembly (11). Remove the cap from connection on the ARD combustion head. Connect fuel tube assembly (11) to the ARD combustion head. Hand tighten fuel tube assembly.

16. Remove the plug from coolant tube assembly (2) and coolant tube assembly (3). Remove the cap from coolant connections on the ARD combustion head. Connect coolant tube assembly (2) and coolant tube assembly (3) to the ARD combustion head. Hand tighten coolant tube assemblies.

17. Position tube assembly clamps (6) onto tube assemblies. Install allen head bolts (5) (not shown) to tube assembly clamps (6). Hand tighten allen head bolts (5).

18. Tighten coolant tube assembly (2) and coolant tube assembly (3) to a torque of 20 N·m (177 lb in).

19. Tighten fuel tube assembly (11) to a torque of 16 N·m (142 lb in).

20. Tighten allen head bolts (5) to a torque of 12 N·m (106 lb in).

21. Turn the fuel supply to the ON position.

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

23. Fill the cooling system to the correct level. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Check" and Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct filling procedure.

24. Perform the ARD ignition test. Refer to Troubleshooting, "ARD Ignition - Test" for the correct filling procedure.