- Engine:
- C9 (S/N: C9Y1-UP)
- Generator Set:
- C9 (S/N: SJB1-UP)
- C9 (S/N: C9A1-UP)
- Marine Engine:
- C9 (S/N: C9B1-UP; CSN1-UP; X9X1-UP; Z9X1-UP; X9Y1-UP)
Introduction
This Special Instruction provides information on installation of the newly designed HEUI pump.
The new HEUI pump helps to prevent drive bearing spalling due to inconsistent force that is applied to the bearing in certain operating conditions.
The overall length of the new HEUI pump is 15 mm (0.6 inch) longer. New fluid connections are required.
Safety
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Personal injury can result from hot coolant. Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained. |
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Contact to high pressure fuel can cause personal injury or death. Do not allow high pressure fuel to contact your skin. |
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Parts List
Note: Table 1 has a list of parts associated with the new pump. Not all of these parts are needed for your engine. Select the parts needed for your engine. Additional parts will be necessary for this repair, utilize existing parts information for your specific engine.
| Old Part Number | New Part Number | Description |
| All | 384-0678 or 20R-1636 | Unit Injector Hydraulic Pump Gp |
| 209-3171 | 387-7159 | Tube As (Single wall high pressure) |
| 241-6923 | 378-8430 | Tube As (Dual wall high pressure ) |
| 221-3463 or 263-1785 | 387-9500 | Tube As (Low-pressure oil line) |
| Components for Fuel Hose | ||
| 192-2184 | 339-1587 (1) |
Hose As |
| 6V-8724 (1) | Elbow | |
| 214-7568 (1) | O-Ring Seal | |
| 228-7089 (1) | O-Ring Seal | |
| Components for Pressure Sensor Fitting | ||
| None | 205-3079 (2) |
Adapter |
| 9S-8003 (2) | Plug | |
| 214-7568 (2) | O-Ring Seal | |
| 214-7567 (2) | O-Ring Seal | |
| ( 1 ) | Use only on the following serial number prefixes: S/N:C9A00001-00196, ; S/N:CSN00001-00898, and ; S/N:C9B00001-00168. |
| ( 2 ) | Use only on the following serial number prefixes: S/N:C9A00001-00500, ; S/N:C9B00001-UP, ; S/N:CSN00001-UP, ; S/N:X9X00001-00488, ; S/N:Z9X00001-00245, and ; S/N:SJB00001-00169 |
Installation Procedure
| NOTICE |
|---|
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component. |
- Perform a cylinder cutout test to identify any injectors that are not operating properly.
- If the engine is equipped with a rectangular aftercooler, drain and remove the aftercooler. Refer to Disassembly and Assembly, SENR9664, "Aftercooler - Remove" for more information, if needed.
- Remove the crankcase breather.
- Clean the exterior area of the pump for the HEUI. Clean the cover, between the cover and the housing, and around the inlet oil line and the fitting to remove any dirt, debris, and oil. Remove inlet oil line and adapter fitting from the pump cover. Use 1U-5718 Vacuum Pump in order to drain the oil out of the pump for the HEUI. Insert the tube on the vacuum pump into the opening in the pump for the HEUI. Refer to Illustration 1 for the correct location. Ensure that the tube is inserted as far as possible into the pump. Once five bottles of oil are removed from the pump, the pump is drained.
Note: DO NOT proceed to Step 5 without draining the oil from the pump for the HEUI.
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| Illustration 1 | g01867833 |
Draining the oil from the pump for the HEUI | |
- Back out the cover bolts from the threads in the pump housing.
The joint that is between the cover and the housing must be free of any dirt, debris, or oil.
Back out the cover bolts from the threads in the pump housing. Do not remove the bolts from the pump cover.
Note: Ensure that no debris falls into the pump when the cover is loosened.
Note: Pulling the bolts out of the cover can result in losing the bolts. Also, the pump cover may fall.
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| Illustration 2 | g01866496 |
- Lift the cover enough to clear the bolts. Then, turn the pump cover clockwise by 90 degrees and place the cover on top of the pump housing. Refer to Illustration
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| Illustration 3 | g01866497 |
- Inspect the coil for debris as described
- Inspect the coil for debris.
The debris will be visible in the form of metal shavings on the coil. Refer to Illustration. If the coil is covered in soot, use a clean magnet to locate the debris.
Note: DO NOT use high-pressure fluid or other cleaning solvents. Debris may be lost during cleaning.
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| Illustration 4 | g03351843 |
Pump for the HEUI (1) Coil | |
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| Illustration 5 | g01943178 |
Coil without debris | |
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| Illustration 6 | g03351850 |
(2) Debris on the coil | |
- If debris is present and/or an injector is inoperable perform the remaining Steps that are in Special Instruction, REHS3819, "Procedure for Troubleshooting and Cleaning the Oil Rail System for the Hydraulic Electronic Unit Injector (HEUI)". Ensure that the system is flushed through six injector bores, two large and six small plugs.
- Cylinder heads that were manufactured prior to January 2006 must relocate the HEUI pressure sensor. Refer to Illustration 7 for the proper location for the HEUI pressure sensor.
- Install plug (3) with seal (4) into the port.
- Install sensor into the cylinder head at cylinder number 4.
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| Illustration 7 | g03344174 |
Close-up view of cylinder head (3) 9S-8003 Plug (4) 214-7567 O-Ring Seal (5) 205-3079 Adapter , and sensor location (if needed) | |
- Install fuel pump (6) .
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| Illustration 8 | g03355201 |
(6) Fuel pump (7) Gear | |
- Position fuel pump (6) and install bolts (8) through the front housing.
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| Illustration 9 | g03345875 |
(6) Fuel pump (8) Bolts | |
- Install elbow (9) with o-ring seal (10) onto the fuel pump. Do not tighten the fitting. Refer to Illustration 10
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| Illustration 10 | g03355149 |
View of 242-7032 Engine Oil Lines Gp (9) 6V-9850 Elbow (10) 228-7089 O-Ring Seal (11) 378-8430 Tube As (12) 8C-8988 Elbow | |
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| Illustration 11 | g03355176 |
Proper tightening sequence for oil line fittings | |
- Install elbow (12) with o-ring seal (10) onto the cylinder head port. Do not tighten the fitting.
- Install tube assembly (11).
- Tighten the fittings to a torque of 45 N·m (33 lb ft), that are shown in Illustration 11 using the proper torque sequence.
- Use the following Steps in order to install the fittings and plugs from the current pump to the new pump. Refer to Illustration 12 for the proper location of the fittings and plugs.
- Install the fitting (10) with o-ring seal (16, 17) .
- Install fitting (22) with o-ring seal (16) .
- Install plug (24) with o-ring seal (16)
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| Illustration 12 | g03345035 |
View of 388-2124 Unit Injection Hydraulic Pump and Mounting Gp (10) 228-7089 O-Ring Seal (13) 068-4174 Elbow (14) 238-5081 O-Ring Seal (15) 6V-8724 Elbow (16) 214-7568 O-Ring Seal (17) 6V-8636 Connector (18) 030-7950 Elbow (19) 238-5082 O-Ring Seal (20) 387-9500 Tube As (21) 387-7159 Tube As (22) 2R-6806 O-Ring Connector (23) 384-0678 or 20R-1636 Unit Injector Hydraulic Pump Gp (24) 9S-8004 Plug | |
- Install elbow (15) with o-ring seal (10, 16) onto the fuel pump.
- Connect the harness assembly to the connector of the fuel pump.
- Install elbow (13) with o-ring seal (14). Refer to Illustration 12 for proper orientation of components.
- Install tube (21) .
- Install tube (20) .
- Replace the 192-2184 Tube As , if equipped, with hose (28) and elbow (26) with o-ring seals (25, 27). Refer to Illustration 13.
Note: Wrap connections with SOLAS tape, if necessary.
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| Illustration 13 | g03345332 |
(25) 228-7089 O-Ring Seal (26) 6V-8724 Elbow (27) 214-7568 O-Ring Seal (28) 339-1587 Hose As | |
- Install the aftercooler, if needed. Refer to Disassembly and Assembly, SENR9664, "Aftercooler - Install" for more information.
- Prime fuel system until fuel pressure is achieved. Disconnect injector harness and crank the engine until oil pressure is achieved.
Note: Do not crank the engine more than 30 seconds.
- Check the engine oil level, and add oil if needed.
- Start the engine and check for any leakage.