PRODUCT SUPPORT PROGRAM TO REMOVE UNIT INJECTOR SLEEVES ON CERTAIN C-9 INDUSTRIAL ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM TO REMOVE UNIT INJECTOR SLEEVES ON CERTAIN C-9 INDUSTRIAL ENGINES

Usage:

SEBE8050-01

July 7, 2002
(Revised July 2002)
U-156
O-129

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*After failure only*	PRODUCT SUPPORT PROGRAM TO REMOVE UNIT INJECTOR SLEEVES ON CERTAIN C-9 INDUSTRIAL ENGINES
1713		PS50476

NOTE: This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS50476" as the Part number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

NOTE: The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

NOTE: This Revised Service Letter replaces the July 7, 2002 Service Letter. Changes have been made to the Rework Procedure.

TERMINATION DATE

July 31, 2004

PROBLEM

Transfer of fuel to coolant at the injector sleeve. Observable fuel ranges from a slight odor to a visible sheen in the top tank of the radiator or over flow tank.

AFFECTED PRODUCT

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Model

Identification Number

C-9

CLJ247, 254, 257, 262-264, 271, 281, 282, 294, 299-303, 310, 311, 313, 316, 317, 319-321, 336-363, 365-373, 376-380, 382-390, 393-397, 399, 400, 402, 403, 406, 408, 409, 411-428, 430, 431, 434-475, 477-481, 483-497, 499-503, 505-512, 514, 516, 517, 520, 521, 523-528, 530-532, 535-539, 541-544, 546-560, 564-567, 569, 570, 572-577, 579-581, 584-590, 594-612, 614-616, 618-621, 628-631, 645-653, 655, 657-661, 676, 733, 735, 770-772, 774-776, 778, 780-782, 786, 790, 791, 793-795, 801, 802, 806, 810, 812, 815, 821, 825, 835, 837, 850, 851, 871, 873-876, 878-880, 885, 887, 896, 897, 900, 906, 910, 914-916, 982-987, 1001, 1002, 1004-1005, 1007-1008 1018

PARTS NEEDED

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Qty	Part Number	Description
1	4C9507	COMPOUND
6	1785037	SLEEVE INJECTOR

NOTE: Some special tools are required.Refer to rework procedure Table 1, 2 and 3.

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Product age	Caterpillar		Dealer Suggested		Customer Suggested
Product age	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-12 mos	100%	4	0	0	0	0
NOTE: This is a 4.0?hr job. NOTE: The special tools listed in Table 1, 2 and 3 are reusable. One set of tools per dealer allowed with affected engines.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Attach. (1-Rework Procedure)

Rework Procedure

Unit Injector - Removal Procedure

First remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".

NOTE: Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

NOTE: 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, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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Table 1	Required Tools
Tool A	Required Tools
Tool A	Part Number	Description	Quantity
	1U7587	Pry Bar	1
	1U5718	Vacuum Pump	1
	1697372	Bottle Assembly	1
	4C4057	Plastic Tubing	1

NOTE: Ensure the injectors are numbered. Use a wax pencil and write the number on the top of the injector. Return the injector to the same bore. We highly recommend the injectors are numbered and safely stored while doing the sleeve rework. Installing the wrong injector into the wrong sleeve will cause poor performance. The fuel and oil must be drained from the cylinder head

Remove fuel line and fitting as needed and drain fuel into a proper container.
Remove injection actuation pressure sensor (2). Allow the engine oil to drain from the ports in the cylinder head before the injectors are removed.

Latch clip

NOTE: Minimal force is needed to lift the latch clip. Too much force will cause the latch clip to separate from the connector.

NOTE: Use a small flat head screwdriver (8) to unlock latch clip (7) on the wiring harness. Lift latch clip (7) by hand.

Disconnect electrical connector from the injector.
Remove socket head bolts from the fuel injector hold down.

NOTE: When possible, remove the fuel injector by hand by twisting the fuel injector and pulling upward. Do not strike or hit the injector when you are removing the injector from the cylinder head. Go to step 6 if you cannot remove the injector by hand.

NOTE: Do not damage the fuel injector during removal. Side loading may cause damage to the fuel injector.

Place Tool A (pry bar) on the flywheel side of injector (5) at location (C). Carefully remove fuel injector (5) from the cylinder head.

NOTE: Do not use a wire brush on the tip of the injector. Damage to the injector will occur.

Inspect the O-ring seals, do not remove the O-ring seals from the fuel injector unless damaged.
Repeat Steps 3 through 7 for the remainder of the fuel injectors.
Evacuate as much fuel and oil as possible from the cylinder head before installing the injector. Several evacuations may be necessary. Use the 1U-5718 Vacuum Pump to remove the fuel and oil from the cylinder head. Use the 169-7372 Bottle Assembly, and the 4C-4057 Clear Plastic Tubing with the Vacuum Pump.

C-9 Engine Unit Injector Sleeve Removal/Install Procedure

Drain coolant from the engine

NOTE: Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Unit Injector Sleeve ? Remove

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Table 2	Required Tools
Tool A	Part Number	Description	Quantity
	1P3042	Plug Tap	1
	2219803	Rubber Plug	1
	2210052	Collar Guide	1
	5N5561	Silicone	1
	4C5552	Brush	1
	4C9507	Vacuum	1
Tool B	9U6858	Bridge Plate	1
	4K0367	Full Nut	1
	2219778	Puller Stud	1
	5P8247	Hard Washer	1
	9U6877	Thrust Bearing	1

Tool A

After the injector is removed from the sleeve, place the rubber plug (small end first) into the bottom of the sleeve.

Place the 2219803 rubber plug into the sleeve and push it through the opening at the bottom of the sleeve.
Apply 5N5561 silicone or grease to the threads of the 1P3042 tap
Place tap into the injector sleeve and slide the 2210052 sleeve guide over the neck of the tap and into the hole.
Using the tap, cut threads into the unit injector sleeve. Swab the excess chips from the top of the sleeve onto the rubber plug.

NOTE: The rubber stopper must remain in the sleeve during the process.

Install bolts (item 5) in bridge plate (item 4). Install the large threaded end (item 7) into the unit injector sleeve. Rotate threaded rod assembly (item 6) in a clockwise direction.

Tool B

(1) Nut (4K0367)

(2) Bearing (9U6877)

(3) Washer (5P8247)

(4) Bridge plate (9U7259)

(5) Bolts (5/16)

(6) Threaded rod puller stud (221-9778)

(7) Threaded end

Install the remaining parts of Tool B on the threaded rod assembly (item 6).
Lubricate the threads on (item 6).
Tighten nut (item 1) in order to remove the unit injector sleeve. Do not use an impact wrench.
After the sleeve is removed, use the large 4C5552 wire brush to remove dirt and sealant from the bore. Squirt isopropyl alcohol or brake cleaner into the bore to remove oil. Use paper towels and swabs to remove all debris from the bore. Ensure the injector bore and fuel rail are clean and free from debris.

NOTE: Any sealant, fuel, oil or debris will prevent the sealant from properly curing. Improper cleaning will lead to a poor sealing surface and leak path.

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Table 3	Unit Injector Sleeve ? Install Required Tools
Tool A	Unit Injector Sleeve ? Install Required Tools
	Part Number	Description	Quantity
	2219777	Sleeve Installer	1
	4C9507	Locktite 620 Sealant	1

NOTE: Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Ensure the o-ring (8T7878) is in place on the 2219777 sleeve installer
Place the 1785037 unit injector sleeve on Tool A.
Clean the sleeve with isopropyl alcohol and wipe dry with as clean paper towel. Note: Make sure the sleeve is free of all debris, oil and fuel.
Apply 4C9507 Locktite 620 sealant (shake well before using, sealant can separate) to the upper land and lower land of the unit injector sleeve.

NOTE: Surfaces to be sealed must be free of oil, grease, fuel, etc.

Install the unit injector sleeve into the injector sleeve bore.
Use a hammer to drive the sleeve into the head until the sleeve bottoms out.
Wipe all excess anaerobic from the injector bore with a paper towel and swab.
Stamp AH on the front left top of the cylinder head near the HEP 8 pump to verify the rework has been completed.

NOTE: Wait approximately two (2) hours at room temperature (70F) before filling the engine with fuel or coolant. Longer curing time is needed at lower temperatures.

Unit injectors ? Installation procedure

NOTE: Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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	Part Number	Description	Quantity
Tool A	1492955	Seal Protector	1
Tool B	1492956	Seal Installer	1

Install injection actuation pressure sensor. Torque the sensor to 10 ± 2 N·m (88 ± 18 lb in).
Install the fuel lines and fittings as needed. Torque to specifications.
Lubricate the O-Ring seals and the sleeve bore of the injector sparingly with clean engine oil.
Install injector in the cylinder head. Position the injector into the cylinder head. Use your hand to install the injector into the cylinder head. Install socket head bolt on the exhaust side of the hold down bracket. Tighten the exhaust side of socket head bolt until the bolt is seated. Install and tighten the inlet side of socket head bolt to a torque of 12 ± 1 N·m (9 ± 1 lb ft).
Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".

NOTE: If the o-rings are damaged and need replaced.

Use Tool (A) and Tool (B) to install the upper high-pressure seal pack.

Install the upper seal pack first. Then install the middle seal pack. Finally, install the bottom O-Ring Seal.
Install Tool (A) on the injector.
Use Tool (B) to install backup rings and O-ring seal on the unit injector. Lubricate the O-ring seals and the backup rings on the unit injector with clean engine oil before installation.

NOTE: The O-ring seals and the backup rings must be installed in the correct orientation. Damaged seals will result in excessive oil consumption or excessive leakage under the valve cover. Use care to prevent nicks or damage to the seals. Visually inspect the injector bores after injectors are installed to make sure the backup ring has not been forced out of the groove. Metal back-up rings can become wedged between the injector body and injector bore giving false torque readings before injector is completely seated.

NOTE: Do not hit or strike the injector during installation. Do not use a wire brush to clean the tip of the injector. Damage to the injector will occur.

NOTE: If you install a new injector the Electronic Trim value must be programmed into the Electronic Control Module. The E-Trim value is a six digit alphanumeric code that is supplied with the data sheet that comes with the new injectors. Use the following menu to program the E-Trim value:

ECM Summary Screen

Service Menu

Calibration

Injector Code Calibration

NOTE: Proper installation of the injector is very important. Damage to the upper high-pressure seals can cause excessive oil leakage under the valve cover. This may cause the engine not to start due to a low actuation pressure. Damage to the lower high-pressure seals may allow high-pressure oil to leak into the fuel supply passage. This will result in excessive oil consumption.