Usage:
Introduction
This Special Instruction contains the necessary procedures and information for converting a Mechanically Unit Injected (MUI) 3516 Engine to a Electronically Unit Injected (EUI) Engine. This instruction is written as general information and will not cover every detail of the conversion because of model variations.
NOTE: Once the conversion is complete this Special Instruction must be given to the customer. This will provide the customer with a current parts list for the engine that has been retrofitted. A new arrangement number will not be assigned. The new parts list from the Special Instructions will be the only means for the customer to order the correct parts for future repairs.
Reference: SEHS8742, Using The 8T8697 Electronic Control Analyzer Programmer (ECAP); SEHS8833, Installing The 7X1180 Internal Expansion Board In The 8T8697 ECAP Service Tool; SEHS9264, Using The 7X1700 Communication Adapter Group; SEHS9343, Using The 3500 Service Program Module; NEEG2500, Pocket Diagnostic Card.
Part Number Index
NOTE: When a remanufactured engine is to be installed as part of the EUI Conversion or the heat shields are to be removed, SEHS9256-01 Thermal Heat Shield Removal and the recommended parts must also be ordered.
EUI Component Location
Front view. Electronic Control Module (1).
Left view. Temperature and speed/timing sensor (2). Wiring harness (3) and Deutsch electrical connector (4).
Rear view. Speed timing sensor (5), manifold sensor (6) and oil pressure sensor (7).
Right view. Wiring harness (8) and Deutsch electrical connector (9).
Component Description
Electronic Control Module (ECM) (1), 70 pin connector (2), connector (3).
The ECM (1) is mounted in the same location as the 3161 governor. The 70 pin connector (2) is located on the right side of the ECM. Connector (3) is used when calibrating the timing sensor.
Coolant temperature sensor (4), coolant gauge sender (5).
The coolant temperature sensor (4) is mounted on the thermostat housing and allows the ECM to monitor engine temperature for cold mode operation. The coolant gauge sender (5) is used to operate a temperature gauge and warning system.
Speed/timing sensor (6).
The speed/timing sensor (6) is mounted on the left side of the flywheel housing.
Speed/timing sensor (6) dowel opening (7), and timing wheel (8).
A dowel opening (7) is used to locate the timing wheel (8) in the correct position on the camshaft. The wide and narrow slots on the timing wheel are used to determine top dead center of number one cylinder and correct engine rotation. The speed timing sensor (6) is self adjusting on installation.
Camshaft dowel (9).
The locating dowel (9) for the timing wheel is in the end of the camshaft.
Timing wheel (8).
The timing wheel (8) is installed on the camshaft taper.
Manifold sensor (10) and oil pressure sensor (11).
The absolute manifold pressure sensor (10) is mounted in the vee of the cylinder block. The sensor is used in conjunction with the atmospheric pressure sensor to calculate manifold gauge pressure. The oil pressure sensor (11) is mounted on the oil manifold at the right rear corner of the cylinder block.
Electronic unit injector.
The electronic unit injector has the same bore dimensions as the MUI. The EUI cylinder head will accept the MUI injector, but the MUI cylinder head will not accept the EUI injector.
Electronic unit injector inside wiring harness.
The wiring harness is routed through the top of the rocker box from the Deutsch connector to the injector.
Component Removal
The number of components that must be replaced will depend on the age of the engine. The following 3516 engine components in the 789 Off Highway Truck were updated as follows:
- * Flywheel Housing - 54Z747
- * Camshaft - 54Z741
- * Cylinder Head - 54Z787
- * Piston - 54Z701
- * Camshaft - 54Z741
On newer engines fewer components must be replaced. If the engine serial number is later than listed above, the component will not be replaced or reworked.
Remove the following components:
- * Cylinder heads
- * Rocker boxes and covers
- * 3161 Governor
- * Rack linkage
- * MUI unit injectors
- * Left rear camshaft
- * Pistons
- * Rocker boxes and covers
NOTE: Some MUI rack linkage will remain in the engine if the engine is being converted to EUI in the chassis.
Removal of Power Setting Screw
Remove Cover (30) and Setscrew (24). Replace Bolt (19) and Pin (26) with short 3/8 inch bolts. These bolts must be installed to prevent oil leaks.
Replace Air Indicator
Remove 8N2694 Air Filter Indicators. Install 7W7417 Indicators (21).
Removal of Air Fuel Ratio Control Lines
Remove 1W2136 Air Fuel Ratio Control Lines Group. Install 2B0858 Plug in place of 19440 Connector (1).
Removal And Installation of Camshaft
Remove left rear camshaft and install 7E5539 Camshaft (3) using 7N3216 Spacer (4), and 5P0076 Bolts (8). Tighten bolts to a torque of 55 ± 10 N·m (40 ± 7 lb ft). Install 5B5821 Pin on engine serial numbers 54Z741 and up.
Removal of Accessory Drive Group
Remove 6K3772 Bolts (19) and 7N5248 Gear (1). Install 6K3771 Bolts in place of 6K3772 Bolts (19). Remove remainder of accessory drive group.
Installation of Connecting Rods and Pistons
Engines serial number 54Z1 thru 54Z700 must have the rods and pistons replaced. Install rods and pistons as indicated.
Install 7E4069 Cooling Jet Assemblies (1) and 7C3722 Jet Retainer Assemblies (2). Put cooling jet (1) in position in the engine block. Make sure the oil holes in the end of the jet are toward the piston. Install retainer (2) and bolts to hold jet (1) in position.
Speed/Timing Sensor Installation
Engine Serial Numbers 54Z747 and Up
Bolt (1).
On engines serial numbers 54Z747 and up the flywheel housing contains a threaded hole. To install the speed/timing sensor remove bolt (1) in the threaded hole.
Speed/timing sensor.
Pry out the nose piece on the 3E0487 Timing Sensor with a small screwdriver. There are slots provided on three sides of the nose piece for the screwdriver. The nose piece should extend approximately 6.35 mm (.25 in) from the threads. Install the sensor and 8L2786 Seal. Nose piece must not extend past outside diameter of timing ring. Tighten sensor to a torque of 40 ± 5 N·m (30 ± 4 lb ft). As the sensor is tightened, the nose piece will contact the gear teeth and move back into the sensor body. The nose piece is at the correct air gap and no other adjustments are required. Connect sensor wiring to the engine wiring harness after the new wiring harness is installed.
Engine Serial Numbers 54Z1 through 54Z746
Engines with serial numbers 54Z1 through 54Z746 must have the flywheel housing reworked to accept the EUI speed/timing sensor. To rework the flywheel housing use the procedure that follows.
Cover Plate Bracket (Fabricate)
Machining Fixture (Fabricate)
Hole Saw Guide (Fabricate)
Timing Sensor Adapter (Fabricate)
Hole Saw Arbor (1) (Purchase), Hole Saw Guide (2) (Fabricate), Hole Saw (3) (Purchased).
Shell Reamer Arbor (1) (Purchase and Machine as Shown), Shell Reamer (2) (Purchase and Machine as Shown).
1. Purchase Shell Reamer and #8 Shell Reamer Arbor and machine as shown. Refer to page 16 in this instruction for supplier name and part numbers.
2. Clean the flywheel housing in the area to be machined.
3. Apply grease to inside of flywheel housing to contain metal chips if machining the flywheel housing on the engine. If the flywheel housing is removed from the engine for machining, clean flywheel housing after machining is completed.
4. Install cover plate bracket to rear of flywheel housing using OS1571 Bolts, OS1590 Bolts, and 5M2894 Washers.
6. Use the hole saw to drill a 48 mm (1.875 in) diameter hole in the flywheel housing. Oil should not be used on the hole saw cutting edge. Oil should be used between the hole saw guide and bushing in the machining fixture. The drill should rotate at 120 rpm (150 rpm max.).
7. Use the 49.2 mm (1.94 in) reamer with a 3/4 inch hex arbor to bore the hole to the final size. The drill should rotate at 120 rpm (150 rpm max.).
8. Remove the machining fixture and cover plate bracket.
9. Deburr the edges of the hole with a hand file.
10. Clean the flywheel housing around the machined area.
11. Apply 7M7456 Compound to the outside of the timing sensor adapter.
12. Install the adapter in the reamed hole taking care not to damage the internal threads of the adapter. The adapter must be flush with the outside of the flywheel housing.
13. Install cam gear and timing ring.
14. Pry out the nose piece on the new 3E0487 Timing Sensor with a small screwdriver. There are slots provided on three sides of the nose piece for the screwdriver. The nose piece should extend approximately 6.35 mm (.25 in) from the threads.
15. Install the sensor and 8L2786 Seal. The nose piece must not extend past outside diameter of timing ring. Tighten sensor to a torque of 40 ± 5 N·m (30 ± 4 lb ft). As the sensor is tightened, the nose piece will contact the gear teeth and move back into the sensor body. The nose piece is at the correct air gap and no other adjustments are required.
16. Check the alignment of the sensor tip with the edge of the timing ring. Connect sensor wiring to the engine wiring harness after the new wiring harness is installed.
NOTE: Do not leave sensor in housing if other work in the housing is not complete.
Installation of Accessory Drive Group
1. Insert idler gear assembly into upper opening passing over larger gear and engage with smaller gear. Roll idler gear into position and assemble idler shaft.
2. Assemble upper drive parts.
Installation of 7E8758 Cylinder Heads
(1) Put 5P3931 Anti-Seize Compound on the threads of the bolts and tighten them as follows:
a. Tighten bolts 1 through 8 in number sequence to ... 30 ± 5 N·m (22 ± 4 lb ft)
b. Tighten bolts 1 through 8 in number sequence to ... 400 ± 35 N·m (300 ± 26 lb ft)
c. Tighten bolts 1 through 8 in number sequence to ... 575 ± 20 N·m (420 ± 15 lb ft)
d. Tighten bolts 9 and 10 to ... 55 ± 10 N·m (40 ± 7 lb ft)
Installation of Fuel Injection Pump Groups
Install 7E9090 Fuel Injection Pump Groups. Lubricate injector with bore No. 2 multipurpose grease. Use 7E2580 Clamp to draw injector into bore. Tighten 7F8698 Bolts to a torque of 65 ± 7 N·m (48 ± 5 lb ft). For injector timing dimension refer to OT specifications.
Installation of Valve Mechanism Group
Install valve mechanism group as indicated.
Crankshaft Positions For Fuel Injector Lash And Valve Lash Setting
Unit Injector Adjustment
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The camshafts must be correctly timed with the crankshaft before an adjustment of the fuel injector lash is made. The timing pins must be removed from the camshafts before the crankshaft is turned or damage to the cylinder block will be the result. |
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The Electronic Control Module produces high voltage. To prevent personal injury make sure the Electronic Control Module is not powered and the fuel injector solenoids are disconnected. |
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1. See chart Crankshaft Positions For Fuel Injector Lash and Valve Lash Setting. With the two crankshaft positions given in the chart, all of the injectors can be checked or adjusted. This will make sure the pushrod lifters are off the lobes and on the base circles of the camshaft.
Before a check or an adjustment can be made, the tooling must be set to the correct dimension as follows:
Adjustment Of Fuel Timing Tools (64.34 mm Fuel Setting)
(1) 6V3075 Dial Indicator (metric). (2) 9U5137 Timing Fixture. (3) 5P4814 Collet. (4) 9U5220 Extension Rod. (5) 9U5138 Set Gauge.
2. Put 9U5220 Rod (4) in timing fixture (2).
3. Put 5P4814 Collet (3) in timing fixture (2).
4. Install the 8S3675 Contact Point on the dial indicator stem.
6. Put the dial indicator and timing fixture on 9U5138 Set Gauge (5) with the magnetic base of the timing fixture on the top surface and the extension rod on the top step.
NOTE: The 9U5138 Set Gauge has two steps. Make sure the step designation is for the 64.34 mm dimension.
7. Move the indicator in the collet until all three of the pointers indicate zero. Tighten the collet.
8. Make sure the top surfaces of injector follower (6) and shoulder (7) are clean and dry.
9. Put 6V3075 Dial Indicator (1) and 9U5137 Timing Fixture (2) in position on the injector to be checked. Make sure the magnetic base of the timing fixture is on the top surface of injector follower (6) and the extension rod is on the top surface of shoulder (7) as shown in illustration.
Fuel Timing Tools In Position
(1) 6V3075 Dial Indicator (metric). (2) 9U5137 Timing Fixture. (6) Injector follower. (7) Shoulder.
10. The dial indicator pointers must indicate 0.00 ± 0.20 mm.
11. If the dial indicator pointers indicate 0.00 ± 0.20 mm, no adjustment is necessary. Proceed to Step 15. If the dial indicator pointers do not indicate 0.00 ± 0.20 mm, do Steps 12 thru 15.
12. Loosen the push rod adjustment screw locknut for the injector to be adjusted.
13. Put 6V3075 Dial Indicator (1) and 9U5137 Timing Fixture (2) in position on the injector to be adjusted. Make sure that the magnetic base of the timing fixture sets flat on the top surface of injector follower (6), and the extension rod (4) is on the top surface of shoulder (7).
Timing And Fuel Setting Tool Group Installed
14. Turn the adjustment screw until zero is read on the dial indicator. Tighten the adjustment screw locknut to a torque of 70 ± 15 N·m (50 ± 11 lb ft) and check adjustment again. If necessary, do this procedure again until the adjustment is correct.
15. Remove the timing bolt from the flywheel when the fuel injector lash adjustment is completed.
Checking And Calibrating Electronic Injection Timing With ECAP (Electronic Control Analyzer And Programmer)
1. Turn the engine off at the ignition switch.
2. Remove the timing calibration plug from the left side of the engine flywheel housing. Install 6V3093 adapter sleeve into the hole for the plug.
3. Rotate the engine until number 1 cylinder is between 20 degrees before or after top dead center (TDC). This positions the flywheel surface in front of the timing calibration hole.
NOTE: The flywheel must be a minimum of 10 degrees before or after top dead center (TDC) to make sure the magnetic pickup is positioned on flywheel surface and not TDC hole.
| NOTICE |
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If the crankshaft is not in the correct position when the magnetic pickup sensor is installed, the magnetic pickup sensor probe will be damaged when the engine is started. |
4. Slide the 6V2197 magnetic pick-up sensor in the adapter sleeve until it contacts the surface on the flywheel.
5. Pull the magnetic pick-up sensor away from the flat surface approximately 1.02 mm (.040 in).
6. Hand tighten the nut on the adapter sleeve to secure the magnetic pick-up in place.
7. Remove the Timing Cal Connector cover and replace it when finished to prevent corrosion. Connect one end of the 7X1695 cable to the Magnetic Pickup Sensor and the other end to the Timing Cal Connector.
8. Connect the ECAP and communication adapter to the Data Link connector in the cab.
9. Warm the engine up and check for engine faults:
Start the engine and run at low idle until the engine has warmed up enough to change from the cold mode operation to the warm mode operation. "Cold Mode" operation is indicated in the upper left hand corner of the ECAP status screen. The "Check Engine" lamp should go out after the engine has started and the five second lamp test is complete.
If the "Check Engine" lamp stays on continuously, the electronic control system has detected a defect. Follow Section 4: Troubleshooting With A Diagnostic Code in Electronic Troubleshooting, 3508 EUI Engine, SENR5191, to determine the diagnostic code.
If the "Check Engine" lamp is flashing on and off intermittently, the electronic control system is detecting an intermittent defect. Follow Section 4: Troubleshooting With A Diagnostic Code in Electronic Troubleshooting, 3508 EUI Engine, SENR5191, to determine the diagnostic code.
10. Select the "Calibrate Timing" screen on the ECAP. For details, refer to Tool Operating Manual, Using the ECAP NEXG4521 Machine Functions Dual Service Program Module SEHS9343.
11. Observe the "Timing Error" bar display on the ECAP.
The end of the "Timing Error" bar display should always be located within the two sets of vertical "Timing Error" tolerance lines. If the "Timing Error" bar is NOT within the two vertical timing tolerance lines, the timing calibration is incorrectly set.
12. To calibrate the timing to the correct setting, press the "space" key on the ECAP keyboard and wait until the ECAP indicates the timing is "CALIBRATED".
NOTE: The ECM will automatically control engine speed to 800 rpm during timing calibration.
13. Verify that the timing has been calibrated by observing the "Timing Error" bar display on the ECAP.
NOTE: If the ECAP display reads COULD NOT CALIBRATE timing, the electronic injection timing has not been set. Recheck the tool installation and tool operation. The engine must not have any diagnostic conditions present during timing calibration and the engine load must remain stable. Follow Section 4: Troubleshooting With A Diagnostic Code in Electronic Troubleshooting, 3508 EUI Engine, SENR5191, to determine the diagnostic code, and if none are present try again to calibrate electronic injection timing.
Electronic Injection Timing Troubleshooting
Electronic injection timing troubleshooting is required if the electronic injection timing is inconsistent or it will not calibrate correctly. Refer to Electronic Troubleshooting, 3508 EUI Engine, SENR5191.
Valve Lash And Injector Timing
Valve lash and injector timing dimensions are made to specific valves. No tolerances are provided for these specifications. A check of the injector timing dimension which shows it to be within ± 0.2 mm (.01 in) is evidence that the setting was made correctly.
Installation of Fuel Injection Lines Group
Install fuel injection lines as indicated.
Installation of Fuel Injector Wiring Harness
Install 7E5315 Base Assemblies. Install 7E5342 Harness Assemblies into groove in top of base assemblies. Connect harness to fuel injector and out through the side of the base assembly. Install 7E8757 Valve Covers.
Installation of Breather Group
1. Install 7E8754 Cover Assemblies (1) and 4W3027 Breather Assemblies (2) on cylinders 12 and 14. Tighten 5P0597 Clamps (9) to a torque of 3 ± 0.5 N·m (27 ± 5 lb in).
3. Attach 9Y4294 Warning Film to the valve covers on cylinders 3, 4, 13 and 14.
Installation of Water Manifolds and Lines
Install 4P3897 Manifolds (1), 102-2665 (2) Manifold, 4P1654 Manifold (17), 4P3896 Manifold (25) and 102-2667 Manifold (26). Install water lines as indicated.
Installation of Turbocharger Oil Lines Group
Install Turbocharger Oil Lines using 7E5335 Brackets.
Installation of Engine Control Group
1. Install 7E5334 Gasket and 7E5319 Plate to front housing using OS1595 Bolts, 5P8245 Washers, OS1566 Bolts, 5P8247 Washers, 9L9132 Washers, and OL1143 Bolts.
2. Install 9X9971 Control Group (ECM) onto 7E5319 Plate using 1A2029 Bolts, 9X6165 Washers, 2W5285 Cover, 8N9885 Gasket, 1B2714 Bolts, 9X9896 Mounts, 9X9838 Spacers and 5M2894 Washers.
NOTE: Fuel lines connect to 4K6297 Elbows.
5. Attach 9Y4294 Warning Film to front face of the ECM.
Installation of 3E5477 Electronic Control Group
Remove cover plate from 7E9084 Engine Control Group (ECM). Install 3E5477 Electronic Control Group (Personality Module). Install cover plate and O-ring seal.
Installation of Alternator Group
Install 9X7803 Charging Alternator Group. Tighten negative terminal nut to a torque of 6.2 ± 0.6 N·m (5 ± 0.4 lb ft). Tighten positive terminal nut to a torque of 7 ± 0.8 N·m (5 ± 0.6 lb ft). Tighten pulley nut to a torque of 102 ± 7 N·m (75 ± 5 lb ft).
Installation of Mounting and Sensor Group
Install 6V1926 Sensor Assemblies, 9X0262 Adapters and 6V5048 Seals.
Installation of Engine Wiring Group
Install 7E5537 Engine Wiring Group as shown in illustrations. Wiring harness brackets and clips must be installed as shown to avoid interference with components such as the fuel priming pump. The vehicle interface plug installs into the cab wall plate and connects to the cab harness. Refer to 789 Cab and Chassis EUI Retrofit, Form No. SEHS9556.
Installation of Mounting and Electrical Sensor Group
1. Install 3E7886 Sensor (6). Tighten sensor to a torque of 13 ± 5 N·m (10 ± 4 lb ft).
2. Install 6V1923 Control Group (24). Tighten control group to a torque of 20 ± 3 N·m (15 ± 2 lb ft).
3. Install 7X5988 Switch Assembly (8), 7N7849 Switch (9), 6V1944 Sensor Assembly (23), 3E0487 Control Group (25) and 6V1964 Sensor Assembly (4). Tighten to a torque of 40 ± 5 N·m (30 ± 4 lb ft).
Installation of Air Lines Group
Install 2W3697 Air Lines Group as shown. Tighten 0S1595 Bolts (14) to a torque of 105 ± 15 N·m (78 ± 11 lb ft). Tighten 9S8752 Nuts (18) and 2K4973 Locknuts to a torque of 25 ± 7 N·m (19 ± 5 lb ft).
Dynamometer Testing
In order to test the 3516 EUI engine on the dynamometer it is necessary to install additional equipment at the test facility. This equipment will act as a cab simulator. Some of this equipment will be made up on site and some will be ordered through the parts system. The wiring to duplicate the dynamometer harness will be assembled using the engine and vehicle wiring diagrams provided. A control panel must also be assembled.
Control Panel Assembly
1. Build a control panel as indicated in the schematics and photo above.
2. Connect a service tool connector to the engine/vehicle connector. This will duplicate that portion of the vehicle harness from the vehicle harness to the service tool connector which includes the ECAP power supply and data link. The connector should be installed on the control panel if possible.
3. Connect 9X9648 Throttle Position Sensor to the engine/vehicle connector. The sensor should be mounted close to the existing throttle actuator so the existing test cell engine control system can be used.
4. If a laptop computer is available, it can be used to view the ECAP screens with a larger format.
5. A secondary shut down switch, installed on the control panel close to the engine, can be connected to the ECM through the vehicle connector. This will provide an additional method of stopping the engine from the instrument panel.
NOTE: The secondary shut down switch is not required but will cause an active diagnostic code if not installed.
6. Install 6V1926 Atmospheric Pressure Sensor to the harness. This sensor can be mounted anywhere convenient in the test cell.
7. Install a power supply to the ECM. This power supply should be protected with the same size fuse as installed on the truck. A 4D1836 Switch should be installed on the control panel.
8. Install a turbocharger inlet pressure sensor on the engine harness. Install the sensor downstream of the air filters.
NOTE: This sensor is not essential, however if it is not installed, a fault will be displayed on the ECAP.
9. Install indicator lights as indicated.
NOTE: EMS oil pressure light signals status of ECM driver so logic is inverted from actual EMS panel.
- * Light On - Oil Pressure OK
- * Light Off - Oil Pressure LOW
NOTE: EMS coolant temperature light signals status of ECM driver so logic is inverted from actual EMS panel.
- * Light On - Coolant Temperature OK
- * Light Off - Coolant Temperature HIGH
Dry Start Priming Procedure
During this 3516 MUI to EUI Conversion sufficient fuel may not remain in the fuel system to start the engine. Perform the following procedure to ensure the engine is receiving sufficient fuel to start the engine.
1. Disconnect the fuel return line below (down stream) from the fuel pressure regulator.
2. Install the gauge/valve assembly.
3. Open the valve and use the hand priming pump to fill the engine with fuel.
4. Continue to prime the engine until air is no longer visible in the fuel. Some foam is acceptable (caused by the fuel pressure regulator).
5. Close the valve and use the hand priming pump to increase system pressure to 206 to 275 kPa (30 to 40 psi).
6. Wait approximately eight to ten minutes.
7. Open the valve.
8. Start the engine.
9. If the engine does not start after 2 or 3 attempts, repeat steps 4 through 7.
10. Shut the engine off. Relieve fuel system pressure below (down stream) from the fuel pressure regulator.
11. Remove the gauge/valve assembly and connect the vehicle fuel return line.
Procedures For Dynamometer Testing
The engine is tested much like a 3516 MUI engine. However, diagnostics will be performed similarly to an engine in chassis.
The ECAP can be used in place of many of the instruments normally in place on the test cell.
The engine will be controlled by the throttle position sensor installed near the control panel. "Stops" should be installed on the throttle position sensor to prevent over-rotation. Over-rotation will cause diagnostic codes to be logged in the ECM. Sensor rotation greater than 99 per cent duty cycle causes sensor to return to 3 per cent duty cycle and engine speed to low idle.
Without EPTC-II Transmission control connected to data link, "Cat Data Link" diagnostic will be active.