Using the 127-3458 Sleeve Replacement Tool Group{1290} Caterpillar

Using the 127-3458 Sleeve Replacement Tool Group{1290}

Usage:

3114, 3116, and 3126 Engines

Introduction

The 127-3458 Sleeve Replacement Tool Group (Combination) is available for use in the replacement of the unit injector sleeves in the cylinder head of all 3114, 3116, and 3126 Engines. This tool group is used on engines equipped with Mechanical Unit Injectors (MUI) or Hydraulic Actuated Electronically Controlled Unit Injectors (HEUI). The 127-3458 Sleeve Replacement Tool Group (Combination) consists of the 127-3462 Sleeve Replacement Tool Group (Supplemental) and the 127-3460 Sleeve Replacement Tool Group (Basic).

The former 4C-4462 Tool Group can be converted to the new 127-3460 Sleeve Replacement Tool Group (Basic) by discarding the former 4C-5575 Driver. The former 4C-8714 and 4C-8715 Guide Bushings can be discarded or reworked. If the bushings are reworked, refer to "Reworking Bushings" section in this Special Instruction. The new driver and guide bushings are part of 127-3462 Sleeve Replacement Tool Group (Supplemental).

The injector sleeves are swaged and roller expanded into the cylinder head at the time of assembly. If it becomes necessary to replace any of these injector sleeves, use the 127-3458 Sleeve Replacement Tool Group (Combination) and the information given in this instruction, to perform the removal and installation procedure.

Due to a product improvement, the lower bore of the injector sleeve has increased in diameter. This increased diameter requires the use of two new tools to remove the sleeve. A new larger tap assembly (128-3102) and compatible puller stud (128-3104) have been developed to remove the new larger diameter injector sleeves. The new sleeves have been installed into 3126 HEUI Engines with 1WM-Up serial number prefixes and 3116 HEUI Engines with 8WL-Up serial number prefixes.

Do not perform any procedure, outlined in this publication, or order any parts until you have read and understood the information contained within.

Reference: Service Manual.

Tool Group Components

NOTE: The illustration on the following pages provides a view of the specific tools. This provides a visual aid for tool identification. Individual tool part numbers are given in the charts for each tool group.

127-3460 Sleeve Replacement (Basic) Tool Group

127-3462 Sleeve Replacement (Supplemental) Tool Group

The following are additional tools and supplies that are necessary for the procedure or tools that make the procedure easier to complete.

Rework Guide Bushings

The former 4C-8714 and 4C-8715 Guide Bushings can be reworked. Grind the head of the bushing to dimension A, shown in the illustration.

Dimension (A) is 41.3 mm (1.62 in)

Injector Sleeve Removal with Cylinder Head Off the Engine

NOTE: The following instructions are written with the understanding that the unit injectors have already been removed from the cylinder head.

1. Injector sleeves can be replaced without removing valves or valve springs.

2. Remove any loose material or deposits from inside the injector sleeve.

(A) Injector sleeve. (7) Stud. (19 or 20) Guide bushing. (24) Sleeve driver. (27) Gage ring. (28) Stop collar.

3. Select a guide bushing (19 or 20) that best fits into the cylinder head injector bore, above the sleeve that is to be removed.

Use large guide bushing (19) if it will slip into the bore with hand force. If the larger bushing cannot be installed as stated, select small guide bushing (20).

4. Remove guide bushing (19 or 20) from the cylinder head. Select tap assembly (30) that will not fit into the lower bore of the injector sleeve. If neither tap assembly will fit into the lower bore of the injector sleeve, select the 122-3396 Tap Assembly (smaller diameter of the two tap assemblies). Tap assembly (30) will be used in Step 31.

5. Install stud (7) into sleeve driver (24). Stud (7) must be installed to full depth. Insert sleeve driver (24) into injector bore.

6. Install previously selected guide bushing (19 or 20) over the shank of sleeve driver (24).

7. Install gage ring (27).

8. Select stop collar (28) that is closest to being flush with top of sleeve driver (24). Each stop collar is different in height.

9. Remove stop collar (28) and gage ring (27).

(A) Injector sleeve. (7) Stud. (19 or 20) Guide bushing. (21) Driver. (24) Sleeve driver. (28) Stop collar.

10. Install previously selected stop collar (28). Make sure gage ring (27) has been removed before proceeding to the next step.

11. Install driver (21). Sleeve driver (24) can now be driven in using either a bench press or a hammer. This will loosen the upper swaged joint of injector sleeve (A). Refer to the information that follows.

Hammer Method

* Use a 1 to 2 kg (2 to 4 lb) hammer to drive driver (21) down until bottom of driver (21) contacts top of stop collar (28). When using the hammer method, avoid excessive hammer force when completing the stroke of the tool.

* Heavier hammer blows will be needed at the beginning of the installation, while only very light hammer blows will be required at the finish.

* The last two or three hammer blows should only be hard enough to make sure that driver (21) has "bottomed out" against stop collar (28).

Bench Press Method

* Put the cylinder head in position on the press with driver (21) centered under the press ram. The centerline of the injector sleeve bore in the cylinder head, must be parallel to the centerline of the press ram.

* Press driver (21) until the bottom of the driver contacts the top of stop collar (28).

* Rotate stop collar (28) or move it up and down to determine if driver (21) is making contact with stop collar (28). The stop collar should not move if driver is "bottomed out" against the stop collar.

NOTE: Do not exceed 81 000 N (18,000 lbs) force.

12. Remove driver (21), stop collar (28) and guide bushing (19 or 20). If sleeve driver (24) can be removed by hand, proceed to Step 19. If sleeve driver (24) cannot be easily removed, follow Steps 13 through 18.

NOTE: Steps 13 through 18 are necessary only if sleeve driver (24) is not easily removed from cylinder head.

(A) Injector sleeve. (5) Washer. (7) Stud. (11) Nut. (13) Thrust bearing. (14) Socket. (15 or 22) Reaction sleeve. (16) Plate. (24) Sleeve driver.

13. Install reaction sleeve (15 or 22) and plate (16).

NOTE: For MUI engines, use 9U-5671 Reaction Sleeve (15). For HEUI engines, use 125-7059 Reaction Sleeve (22).

14. Put 5P-3931 Anti-Seize Compound or 6V-4876 Molykote Paste Lubricant on the threaded stud (7).

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NOTICE

Failure to use 5P-3931 Anti-Seize Compound or 6V-4876 Molykote Paste Lubricant may cause damage to the threads of nut (11) and threaded stud (7).

15. Position thrust bearing (13) on plate (16).

16. Put washer (5) on thrust bearing (13).

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NOTICE

Failure to use washer (5) may cause damage to thrust bearing (13).

17. Install nut (11) on threaded stud (7).

18. Use deep socket (14) and a 1/2 inch square drive impact wrench, 8H-8557 Ratchet Wrench, or equivalent, to pull sleeve driver (24) from the cylinder head.

(A) Injector sleeve. (1) Nut. (2) Washer. (3) Lower pilot. (4) Tap. (12) Socket. (19 or 20) Guide bushing.

19. Insert lower pilot (3) into sleeve (A), then install washer (2), and nut (1), loosely, at the bottom side of the cylinder head.

NOTE: Make sure the threads of tap (4) are sharp and clean before threading it into injector sleeve.

20. Use clean engine oil or cutting oil to lubricate the cutting threads of tap (4). Install tap (4) in injector sleeve (A). Put the pilot end of the tap in the pilot bore of lower pilot (3).

21. Install previously selected guide bushing (19 or 20) over the shank of tap (4) and into the cylinder head injector bore.

22. Tighten nut (1) on lower pilot (3). This will prevent the injector sleeve from turning during the thread cutting procedure.

23. Put socket (12) on tap (4). Use a 1/2 inch square drive ratchet wrench to drive tap (4).

24. Cut threads in injector sleeve by turning the tap in a clockwise (CW) direction, until the tap comes in contact with the top surface of lower pilot (3).

NOTE: If starting the tap is difficult, lightly hit the tap with a plastic hammer or equivalent. This will help start the tap.

25. Remove tap (4) and guide bushing (13).

26. Use 4C-6774 Vacuum Gun Kit to clean any debris from the newly cut threads. Compressed air is required to operate the vacuum gun.

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NOTICE

Use a 6V-6194 Needle Nose Pliers, or equivalent, to remove any large debris from the bore that the 4C-6774 Vacuum Gun Kit did not remove. Debris that is not removed, can cause engine damage.

27. Remove nut (1) and washer (2) from lower pilot (3).

28. Use a 1U-7262 Magnet or equivalent to remove lower pilot (3).

(A) Injector sleeve. (1) Nut. (2) Washer. (19 or 20) Guide bushing. (30) Tap. (31) Hex socket flat head bolt.

29. Insert bolt (31) into the bottom of injector sleeve (A). Install washer (2) and nut (1).

30. Tighten nut (1) on bolt (31). This will prevent the injector sleeve from turning during the thread cutting procedure.

NOTE: Make sure the threads of tap (30) are sharp and clean before threading it into injector sleeve.

31. Use clean engine oil, or cutting oil, to lubricate the cutting threads, when using the previously selected tap assembly (30). Install tap in injector sleeve (A).

32. Install previously selected guide bushing (19 or 20) over the shank of previously selected tap assembly (30) and into the cylinder head injector bore.

33. Use a 4C-6307 Adjustable Wrench or a 1U-7878 Socket, 1U-7121 Short Extension, and a 3/8 inch Ratchet to cut threads in the injector sleeve by turning tap (30) in a clockwise (CW) direction, until the tap bottoms out.

34. Remove the tap and guide bushing.

35. Use 4C-6774 Vacuum Gun Kit to clean any debris from the newly cut threads. Compressed air is required to operate the vacuum gun.

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NOTICE

Use a 6V-6194 Needle Nose Pliers, or equivalent, to remove any large debris from the bore that the 4C-6774 Vacuum Gun Kit did not remove. Debris that is not removed can cause engine damage.

36. Remove nut (1) and washer (2) from bolt (31). Do not remove bolt (31) at this time.

37. Select puller stud (29) compatible with the tap assembly used to cut threads into the injector sleeve. Install puller stud into injector sleeve (A) to full depth. The approximate depth of thread engagement is 13 mm (.5 in).

NOTE: If puller stud (29) will not engage to this depth, continue to cut threads until this depth is achieved.

(A) Injector sleeve. (B) Puller stud and puller sleeve must be in contact. (23) Socket. (29) Puller stud. (31) Hex socket flat head bolt. (32) Puller sleeve.

38. Install puller sleeve (32) into the injector sleeve (A) to full depth, using 126-4949 Socket (23). Hand tighten only. The approximate depth of thread engagement is 9.5 mm (.38 in).

NOTE: If puller sleeve (32) will not engage to this depth, continue to cut threads until this depth is achieved.

39. Turn puller stud (29) counterclockwise (CCW) until it firmly contacts puller sleeve (32) at point (B). This should be between zero and one half turn.

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NOTICE

Failure to make sure puller stud (29) is in contact with puller sleeve (32) at point (B) may cause the threads to strip out of the upper portion of injector sleeve (A). This can result in removing only the lower portion of the injector sleeve.

(A) Injector sleeve. (B) Puller stud and puller sleeve must be in contact. (5) Washer. (11) Nut. (13) Thrust bearing. (14) Socket. (15 or 22) Reaction sleeve. (16) Plate. (29) Puller stud. (31) Hex socket flat head bolt. (32) Puller sleeve.

40. Install reaction sleeve (15 or 22) and plate (16).

41. Put 5P-3931 Anti-Seize Compound or 6V-4876 Molykote Paste Lubricant on the threads of puller stud (29).

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NOTICE

Failure to use 5P-3931 Anti-Seize Compound or 6V-4876 Molykote Paste Lubricant may cause damage to the threads of nut (11) and puller stud (29).

42. Position thrust bearing (15) on plate (18).

43. Put washer (5) on thrust bearing (15).

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NOTICE

Failure to use washer (5) may cause damage to thrust bearing (15).

44. Install nut (11) on puller stud (29).

45. Use deep socket (14) and a 1/2 inch square drive impact wrench, or 8H-8557 Ratchet Wrench, or equivalent, to pull injector sleeve (A) from the cylinder head.

In some instances, the threads may strip from the upper portion of the injector sleeve, resulting in removing only the lower portion of the injector sleeve. If this occurs, refer to procedure "Removing Upper Portion of Injector Sleeve" in this Special Instruction.

NOTE: The upper bore in the cylinder head is small enough that the injector sleeve must be pulled, with force, through that bore also.

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NOTICE

As soon as the injector sleeve pulls free from its lower bore, stop pulling, and manually lift the puller assembly (and injector sleeve) far enough to center the injector sleeve in the upper bore and hand tighten nut (11), before using the wrench to pull the injector sleeve through the upper bore. Failure to center the sleeve in the upper bore may result in damage to the cylinder head or the tool.

46. Remove nut (11), washer (5), thrust bearing (13), plate (16) and reaction sleeve (15 or 22).

47. Loosen and remove the injector sleeve from puller stud (29) and puller sleeve (32). If the injector sleeve cannot be removed by hand, use release block (10) as follows:

* Position the release block in a vise. Tighten the vise just enough to retain the release block.

* Put the threaded (stem) end of bolt (31) into release block (10), then install washer (2) and nut (1) to retain the sleeve in the release block.

* Use two 4C-6307 Adjustable Wrenches to turn sleeve (32) and puller stud (29) and separate the tools from the injector sleeve.

Injector Sleeve Installation with Cylinder Head Off the Engine

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NOTICE

Before installing a new injector sleeve, make sure the grooves in the injector bore are free from metal shavings and retaining compound.

(19 or 20) Guide bushing. (25) Reamer group.

1. Select a guide bushing (19 or 20) that best fits into the cylinder head injector bore, above the injector sleeve that was removed.

Use large guide bushing (19) if it will slip into the bore with hand force. If the larger guide bushing cannot be installed with hand force, select small guide bushing (20).

2. Install previously selected guide bushing (19 or 20) and reamer group (25).

a. If reamer can be pushed into lower bore and turned by hand, reaming is not necessary; proceed to Step 3. If reaming is necessary, proceed to Step 2b.

b. Use 4C-9929 Electric Drill or 4C-9928 Cordless Drill (if electricity is not available) with reamer group (25) to ream the small bore at the bottom of the injector sleeve bore.

NOTE: Due to the machining tolerances for this hole in the cylinder head, Step 2 is necessary to make sure the hole is the correct size. The hole is used as a pilot for the small end of swage assembly (6) during injector sleeve installation. It is also used for the pilot of reamer (9) during injector seat reaming.

3. Remove reamer group (25) and guide bushing (19 or 20) from cylinder head.

4. Use large bore brush (8) with an electric drill to clean the injector sleeve bores in the cylinder head. If necessary, use a small pick and/or emery cloth to remove any remaining particles of copper or retaining compound.

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NOTICE

To prevent engine damage, remove all cutting chips and debris from the cylinder head fuel gallery and coolant passages. Use a cotton swab, lightly coated with grease, to aid in the removal of any particles.

5. Small bore brushes (17 and 18) can be used with an electric drill to clean the small bore at the bottom of the cylinder head. If needed, a 9U-7237 Drill Extension can be used with brush (17 or 18).

NOTE: Sleeve cleaning brush (17) is used to clean the inside of an injector sleeve during injector replacement.

6. Using 4C-4079 Component Cleaner, spray the inside of each injector sleeve bore in the cylinder head, and the outside of each injector sleeve. Permit the cleaner to dry thoroughly.

7. Use 6V-1541 Quick Cure Primer to spray the inside of each injector sleeve bore in the cylinder head, and the outside of each injector sleeve. Permit the primer to dry thoroughly.

(A) Injector sleeve. (B) Locations to coat with 7M-7456 Bearing Mount or 9S-3263 Thread Lock. (C) Do not apply bearing mount or thread lock in this area.

8. Apply a coat of 7M-7456 Bearing Mount or 9S-3263 Thread Lock to the injector sleeve bore in the cylinder head at locations (B).

a. Apply the bearing mount or thread lock to the cylinder head, using a cotton swab.

b. Make sure there is no bearing mount or thread lock at location (C).

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NOTICE

Bearing mount or thread lock applied in area C may result in improper sealing of the injector sleeve.

9. Install all injector sleeves (A) into cylinder head before proceeding with Step 10. Wipe away any excess retaining compound from inside or around the injector sleeve.

(A) Injector sleeve. (6) Swage Assembly. (19 or 20) Guide bushing. (21) Driver.

10. Use either 5P-3931 Anti-Seize Compound, 6V-4876 Molykote Paste Lubricant, or grease, to lubricate swage assembly (6) and upper inside bore of the injector sleeve.

11. Put swage assembly (6) into the injector sleeve. Push the injector sleeve all the way to the bottom of its bore in the cylinder head.

12. Install previously selected guide bushing (19 or 20) over the swage assembly and into the bore.

13. Position driver (21) over swage assembly (6).

Swage assembly (6) can now be driven in using either a bench press or a hammer. Refer to the information that follows.

(A) Injector sleeve. (6) Swage assembly. (19 or 20) Guide bushing. (21) Driver.

Hammer Method

* Use a 1 to 2 kg (2 to 4 lb) hammer to drive the assembly into the injector sleeve. When using the hammer method, avoid excessive hammer force when completing the stroke of the tool.

Heavier hammer blows will be needed at the beginning of the installation, while only very light hammer blows will be required at the finish.

* The last two or three hammer blows should only be hard enough to make sure that the driver has "bottomed out" against the guide bushing.

Bench Press Method

* Put the cylinder head in position on the press with driver (21) centered under the ram of the press. The centerline of the injector sleeve bore in the cylinder head, must be parallel to the centerline of the press ram.

* Press swage assembly (6) into injector sleeve (A) until the bottom of driver (21) contacts the top of guide bushing (19 or 20).

NOTE: Do not exceed 18 000 N (4,000 lbs) force.

(5) Washer. (11) Nut. (13) Thrust bearing. (14) Socket. (15 or 22) Reaction sleeve. (16) Plate.

14. Use reaction sleeve (15 or 22), plate (16), thrust bearing (13), washer (5), nut (11) and socket (14) to pull the swaging tool out of the installed injector sleeve.

a. Install reaction sleeve (15 or 22) and plate (16) over the threaded stem of swage assembly (6).

b. Put 5P-3931 Anti-Seize Compound or 6V-4876 Molykote Paste Lubricant on the threaded stem of swage assembly (6).

c. Position thrust bearing (13) on plate (16).

d. Put washer (5) on thrust bearing (13).

e. Install nut (11) on the threaded stem of swage assembly (6).

f. Use deep socket (14) and a 1/2 inch square drive impact wrench (or a 1/2 inch drive ratchet wrench) to pull the swage assembly from the cylinder head.

g. Wipe away any excess lubricant or retaining compound that may be in either the injector bore or in the injector sleeve.

h. Wipe away any excess retaining compound from swage assembly.

(A) Injector sleeve. (26) Roller expander.

15. Put a coating of clean engine oil on roller expander (26). Make sure the rollers are completely covered with oil.

16. Pull mandrel out of roller expander (26) as far as possible. While holding mandrel out, insert roller expander (26) all the way into injector sleeve (A).

17. Install 1U-7845 Socket (35), or equivalent, on 4C-6936 Torque Wrench, or equivalent. Put the torque wrench with socket (35) on the hex portion of the roller expander mandrel. Turn the torque wrench in a clockwise (CW) direction until a torque of 120 cm kg (100 lb in or 8.0 lb ft) is achieved or the turning torque stops increasing.

NOTE: A click-type 4C-6936 Torque Wrench is more convenient to use for the operation in Step 17, although a dial-type torque wrench is acceptable. If a dial-type 9S-7354 Torque Wrench is to be used, set the dial for 11 N·m (100 lb in).

18. When the specified torque is reached, or the turning torque stops increasing, stop turning the roller expander in the clockwise (CW) direction. Now turn the roller expander in the counterclockwise (CCW) direction until it is loose inside the injector sleeve.

19. Remove roller expander (26) from injector sleeve.

20. Clean the roller expander, especially the rollers, to remove any traces of retaining compound, that may have come from the injector sleeve.

NOTE: When the use of roller expander (26) is completed, clean it thoroughly using either 1U-8803 Cleaner Concentrate or 4C-4079 Component Cleaner. After cleaning, put a coat of 1U-8265 Penetrating Oil or 1U-8809 Rust Preventive on the roller expander, then store in tool case.

21. Wipe away any excess lubricant or retaining compound that may be in either the injector bore or in the injector sleeve.

(9) Reamer assembly. (19 or 20) Guide bushing.

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NOTICE

Guide bushing (19 or 20) must be used to make sure the reamer is properly centered in the hole and to prevent cutting the injector sleeve too deeply. If the reaming procedure is not done correctly, the injector sleeve must be removed and replaced.

22. Install previously selected guide bushing (19 or 20) into the bore.

23. Apply a generous amount of clean grease to lubricate the cutting area of reamer assembly (9). Insert the reamer assembly into the guide bushing.

NOTE: Applying grease will not only help to lubricate the reamer assembly, but also helps retain the cutting chips produced in the reaming process.

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NOTICE

For correct sealing of combustion gas, the injector seat must be free of machining chatter and scratches.

24. Using a 1U-7153 Speed Handle, with light but even pressure, turn reamer assembly (9) in the clockwise (CW) direction. (The reamer assembly will cut aggressively.)

Check cutting progress often. Stop cutting when the injector seat is full faced or when the shoulder of the reamer assembly comes in contact with the guide bushing.

If the injector seat does not machine to a 360 degree full face, the injector sleeve must be removed. Install another injector sleeve and repeat the reaming procedure.

NOTE: It is best to stop cutting immediately when the seat is full face, so only the minimum amount of material is removed. It helps to retain as much material as possible, in the event that a future reaming procedure is necessary. Maximum reamer depth occurs when shoulder of the reamer assembly contacts the guide bushing.

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NOTICE

Do not resharpen the reamer head of reamer assembly (9). If the reamer becomes dull, order a replacement 4C-5564 Reamer Head. The reamer head is precision machined and resharpening will cause an improperly reamed injector seat. This will result in combustion gas leaks between the injector and injector sleeve.

25. Remove any lubricants or copper particles that may be either in, or on, the injector sleeve. Be sure to thoroughly clean the cylinder head fuel gallery.

Injector Sleeve Removal with Cylinder Head On the Engine

This procedure is applicable only if clearance above the engine permits. In some applications removal of the cylinder head may be required due to space limitations. Although not required, removal of the valve springs provides easier access when installing the injector sleeve.

NOTE: Prior to removal of sleeve, ensure that coolant is drained below head level.

1. If valve springs are to be removed, follow Steps 2 through 5. If valve springs are not removed, proceed to Step 6.

2. Turn the engine crankshaft to put the piston at top center (TC) for the cylinder that is to have the injector sleeve replaced. Piston position can be determined through the unit injector bore, after the unit injector is removed.

3. Install a 2J-6274 O-ring Seal on the valve stem of each of the valves for the affected cylinder.

4. With the valves UP, in the CLOSED position, push an O-ring seal down the stem of each valve until it comes in contact with the top of the valve guide. This will hold the valves in the CLOSED position when the crankshaft is moved to lower the piston in the cylinder.

5. Rotate the crankshaft to lower the piston approximately 51 mm (2.0 in) below TC (top center) for the cylinder having the injector sleeve replaced. (This dimension can be measured through the unit injector bore.) With the piston in this position, it will not interfere with the installation of lower pilot (3).

6. Remove any loose material or deposits, from inside the injector sleeve, that would prevent lower pilot (3) from seating squarely in the sleeve.

7. Apply a coat of grease to the inside bottom part of the injector sleeve. This will aid in keeping copper chips from falling through the injector sleeve and collecting on top of the piston.

8. Select a guide bushing (19 or 20) that best fits into the cylinder head injector bore, above the sleeve that is to be removed.

Use the large guide bushing (19) if it will slip into the bore with hand force. If the larger guide bushing cannot be installed as stated, select the smaller guide bushing (20).

9. Remove guide bushing (19 or 20) from the cylinder head. Select tap assembly (30) that will not fit into the lower bore of the injector sleeve. If neither tap assembly will fit into the lower bore of the injector sleeve, select the 122-3396 Tap Assembly (smaller diameter of the two tap assemblies). This tap will be used in Step 35.

(A) Injector sleeve. (7) Stud. (19 or 20) Guide bushing. (24) Sleeve driver. (27) Gage ring. (28) Stop collar.

10. Install stud (7) into sleeve driver (24). Stud (7) must be installed to full depth. Insert sleeve driver (24) into injector bore.

11. Install previously selected guide bushing (19 or 20) over the shank of sleeve driver (24).

12. Install gage ring (27).

13. Select stop collar (28) that is the closest to being flush with the top of sleeve driver (24). Each stop collar is different in height.

14. Remove stop collar (28) and gage ring (27).

(A) Injector sleeve. (7) Stud. (19 or 20) Guide bushing. (21) Driver. (24) Sleeve driver. (28) Stop collar.

15. Install previously selected stop collar (28).

16. Install driver (21). Sleeve driver (24) can now be driven in, using a hammer.

17. Use a 1 to 2 kg (2 to 4 lb) hammer to drive driver (21) until the bottom of the driver contacts the top of stop collar (28).

NOTE: When using the hammer method, avoid excessive hammer force when completing the stroke of the tool. Heavier hammer blows will be needed at the beginning of the installation, while only very light hammer blows will be required at the finish. The last two or three hammer blows should only be hard enough to make sure that driver (21) has "bottomed out" against stop collar (28).

18. Remove driver (21), stop collar (28), and guide bushing (19 or 20). If sleeve driver (24) can be easily removed by hand, proceed to Step 25. If sleeve driver (24) cannot be easily removed, follow Steps 19 through 24.

NOTE: Steps 19 through 24 are necessary only if sleeve driver (24) is not easily removed from head.

(A) Injector sleeve. (5) Washer. (7) Stud. (11) Nut. (13) Thrust bearing. (14) Socket. (15 or 22) Reaction sleeve. (16) Plate. (24) Sleeve driver.

19. Install reaction sleeve (15 or 22) and plate (16).

20. Put 5P-3931 Anti-Seize Compound or 6V-4876 Molykote Paste Lubricant on the threaded stud (7).

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NOTICE

Failure to use 5P-3931 Anti-Seize Compound or 6V-4876 Molykote Paste Lubricant may cause damage to the threads of nut (11) and threaded stud (7).

21. Position thrust bearing (13) on plate (16).

22. Put washer (5) on thrust bearing (13).

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NOTICE

Failure to use washer (5) may damage the thrust bearing.

23. Install nut (11) onto threaded stud (7).

24. Use deep socket (14) and a 1/2 inch square drive impact wrench, 8H-8557 Ratchet Wrench, or equivalent, to pull sleeve driver (24) from the cylinder head.

(3) Lower pilot. (4) Tap. (19 or 20) Guide bushing. (12) Socket.

25. Insert lower pilot (3) into the injector sleeve.

NOTE: Make sure threads of tap (4) are sharp and clean.

26. Use clean engine oil or cutting oil to lubricate the cutting threads of tap (4). Install tap into the injector sleeve. Put the pilot end of the tap into the pilot bore of lower pilot (3).

27. Install previously selected guide bushing (19 or 20) over the pilot diameter of the cutting tool and into the injector bore in the cylinder head.

28. Put socket (12) on tap (4). Use a 1/2 inch square drive ratchet wrench to drive tap (4).

29. Cut threads in the injector sleeve by turning the tap in a clockwise (CW) direction until the tap comes in contact with the top surface of lower pilot (3).

NOTE: If starting the tap is difficult, lightly hit the tap with a plastic hammer, or equivalent. This will help start the tap.

NOTE: If the sleeve turns in its bore during this procedure, it will be necessary to remove the cylinder head from the engine. Once removed, washer (2) and nut (1) can be installed to prevent the injector sleeve from turning. It will also then be necessary to remove the injector sleeve according to the procedure given in "Injector Sleeve Removal with Cylinder Head Off the Engine".

30. Carefully remove tap (4) and guide bushing (13), to prevent cutting chips from falling through the hole in the injector sleeve and onto the top of the piston.

31. Use 4C-6774 Vacuum Gun Kit to clean any debris from the newly cut threads. Compressed air is required to operate the vacuum gun.

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NOTICE

To prevent engine damage, use a 6V-6194 Needle Nose Pliers, or equivalent, to remove any large debris from the bore that the 4C-6774 Vacuum Gun Kit did not remove.

32. Use a 1U-7262 Magnet or equivalent to remove lower pilot (3).

(A) Injector sleeve. (19 or 20) Guide bushing. (30) Tap. (31) Hex socket flat head bolt.

33. Insert bolt (31) into the bottom of injector sleeve (A).

34. Make sure the threads of tap (30) are sharp and clean.

35. Use clean engine oil, or cutting oil, to lubricate the cutting threads, when using the previously selected tap assembly (30). Install tap assembly in the injector sleeve (A).

36. Install previously selected guide bushing (19 or 20) over the shank of previously selected tap assembly (30) and into the cylinder head injector bore.

37. Use a 4C-6307 Adjustable Wrench or a 1U-7878 Socket, 1U-7121 Short Extension, and a 3/8 inch Ratchet to cut threads in the injector sleeve by turning tap (30) in a clockwise (CW) direction, until the tap bottoms out.

38. Remove the tap and the guide bushing.

39. Use 4C-6774 Vacuum Gun Kit to clean any debris from the newly cut threads. Compressed air is required to operate the vacuum gun.

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NOTICE

To prevent engine damage, use a 6V-6194 Needle Nose Pliers, or equivalent, to remove any large debris from the bore that the 4C-6774 Vacuum Gun Kit did not remove.

(A) Injector sleeve. (B) Puller stud and puller sleeve must be in contact. (23) Socket. (29) Puller stud. (31) Hex socket flat head bolt. (32) Puller sleeve.

40. Select puller stud (29) compatible with the tap assembly used to cut threads into the injector sleeve. Install puller stud into the injector sleeve (A). The approximate depth of thread engagement is 13 mm (.5 in).

NOTE: If puller stud (29) will not engage to this depth, continue to cut threads until this depth is achieved.

41. Install puller sleeve (32) into the injector sleeve (A) using a 126-4949 Socket (23). Hand tighten only. The approximate depth of thread engagement is 9.5 mm (.38 in).

NOTE: If puller sleeve (32) will not engage to this depth, continue to cut threads until this depth is achieved.

42. Turn puller stud (29) counterclockwise (CCW) until puller stud (29) contacts puller sleeve (32) at point (B). This should be between zero and one half turn.

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NOTICE

Failure to make sure puller stud (29) is in contact with puller sleeve (32) at point (B) may cause the threads to strip out of the upper portion of injector sleeve (A). This can result in removing only the lower portion of the injector sleeve.

(A) Injector sleeve. (B) Puller sleeve and puller stud must be in contact. (5) Washer. (11) Nut. (13) Thrust bearing. (14) Socket. (15 or 22) Reaction sleeve. (16) Plate. (29) Puller stud. (31) Hex socket flat head bolt. (32) Puller sleeve.

43. Install reaction sleeve (15 or 22) and plate (16).

44. Put 5P-3931 Anti-Seize Compound or 6V-4876 Molykote Paste Lubricant on the threads of puller stud (29).

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NOTICE

Failure to use 5P-3931 Anti-Seize Compound or 6V-4876 Molykote Paste Lubricant may cause damage to the threads of nut (11) and puller stud (29).

45. Position thrust bearing (13) onto plate (16).

46. Put washer (5) on thrust bearing (13).

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NOTICE

Failure to use washer (5) may damage thrust bearing (13).

47. Install nut (11) on puller stud (29).

48. Use deep socket (14) and a 1/2 inch square drive impact wrench, or 8H-8557 Ratchet Wrench, or equivalent, to pull injector sleeve (A) from the cylinder head.

NOTE: The upper bore in the cylinder head is small enough that the injector sleeve must be pulled, with force, through that bore also.

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NOTICE

As soon as the injector sleeve pulls free from its lower bore, stop pulling, and manually lift the puller assembly (and injector sleeve) far enough to center the injector sleeve in the upper bore and hand tighten nut (11), before using the wrench to pull the injector sleeve through the upper bore. Failure to center the sleeve in the upper bore may result in damage to the cylinder head or the tool.

49. Remove nut (11), washer (5), thrust bearing (13), plate (16) and reaction sleeve (15 or 22).

50. Loosen and remove the injector sleeve from puller sleeve (32) and puller stud (29). If the injector sleeve cannot be removed by hand, use release block (10) as follows:

* Position release block (10) in a vise. Tighten the vise just enough to retain the release block.

* Put the threaded (stem) end of bolt (31) into the release block, then install washer (2) and nut (1) to retain the sleeve in the release block.

* Use two 4C-6307 Adjustable Wrenches to turn puller sleeve (32) and puller stud (29) and separate the tools from the injector sleeve.

Injector Sleeve Installation with Cylinder Head On the Engine

This procedure is only applicable if clearance above the engine permits. In some applications removal of the cylinder head may be required due to space limitations.

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NOTICE

Before installing a new injector sleeve, make sure the grooves in the injector bore are free from metal shavings. Remove any copper shavings from the grooves with a 9U-6859 Pick Set. If the shavings are not removed, the injector will not be correctly installed and engine damage could result.

(19 or 20) Guide bushing. (25) Reamer group.

1. Select a guide bushing (19 or 20) that best fits into the cylinder head injector bore, above the injector sleeve that is to be removed.

Use large guide bushing (19) if it will slip into the bore with hand force. If the larger guide bushing cannot be installed with hand force, select small guide bushing (20).

2. Apply a coat of grease to reamer. This will aid in keeping copper chips from falling through the injector bore and collecting on top of the piston.

3. Install previously selected guide bushing (19 or 20) and reamer group (25).

a. If reamer can be pushed into lower bore and turned by hand, reaming is not necessary; proceed to Step 4. If reaming is necessary, proceed with Step 3b.

b. Use 4C-9929 Electric Drill or 4C-9928 Cordless Drill (if electricity is not available) with reamer group (25) to ream the small bore at the bottom of the injector sleeve bore.

4. Remove reamer group (25) and guide bushing (19 or 20) from cylinder head.

5. Use 4C-6774 Vacuum Gun Kit to clean any debris from the injector bore. Compressed air is required to operate the vacuum gun.

6. Wipe away any excess grease from the injector bore and injector sleeve (A).

7. Use large bore brush (8) with an electric drill to clean the injector sleeve bore(s) in the cylinder head. If necessary, use a small pick and/or emery cloth to remove any remaining particles of copper or retaining compound.

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NOTICE

To prevent engine damage, remove all cutting chips and debris from the cylinder head fuel gallery and coolant passages. Use a cotton swab, lightly coated with grease, to aid in the removal of any particles.

8. Small bore brushes (17 and 18) can be used with an electric drill to clean the small bore at the bottom of the cylinder block. If brush (17 or 18) does not reach the bottom bore, use a 9U-7237 Drill Extension.

NOTE: Sleeve cleaning brush (17) is also used to clean the inside of an injector sleeve during unit injector replacement.

9. Using 4C-4079 Component Cleaner, spray the inside of each injector sleeve bore in the cylinder head and the outside of each injector sleeve. Permit the cleaner to dry thoroughly.

10. Use 6V-1541 Quick Cure Primer to spray the inside of each injector sleeve bore in the cylinder head. Permit the primer to dry thoroughly.

(A) Injector sleeve. (B) Locations to coat with 7M-7456 Bearing Mount or 9S-3263 Thread Lock. (C) Do not apply bearing mount or thread lock in this area.

11. Apply a coat of 7M-7456 Bearing Mount or 9S-3263 Thread Lock to the injector sleeve bore in the cylinder head at locations (B).

a. Apply the bearing mount or thread lock to the cylinder head, using a cotton swab.

b. Make sure there is no bearing mount or thread lock at location (C).

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NOTICE

Bearing mount or thread lock applied in area C may result in improper sealing of the injector sleeve.

12. Install all injector sleeves (A) into cylinder head before proceeding with Step 13. Wipe away any excess retaining compound from inside or around the injector sleeve.

(A) Injector sleeve. (6) Swage assembly. (19 or 20) Guide bushing. (21) Driver.

13. Use 5P-3931 Anti-seize Compound or 6V-4876 Molykote Paste Lubricant, to lubricate swage assembly (6) and the upper inside bore of the sleeve.

14. Put swage assembly (6) into the injector sleeve. Push the injector sleeve all the way to the bottom of its bore in the cylinder head.

15. Install previously selected guide bushing (19 or 20) over the shank of swage assembly (6).

16. Position driver (21) over swage assembly (6).

(A) Injector sleeve. (6) Swage assembly. (19 or 20) Guide bushing. (21) Driver.

Swage assembly (6) can now be driven in with a hammer as follows:

* Use a 1 to 2 kg (2 to 4 lb) hammer to drive the swage assembly into the injector sleeve. Avoid excessive hammer force when completing the stroke of the tool. Heavy hammer blows will be needed at the beginning of the installation, but only light hammer blows will be required at the finish of the installation procedure.

* The last two or three hammer blows should only be hard enough to make sure that the driver has "bottomed out" against the guide bushing.

(5) Washer. (11) Nut. (13) Thrust bearing. (14) Socket. (15 or 22) Reaction sleeve. (16) Plate.

17. Use reaction sleeve (15 or 22), plate (16), thrust bearing (13), washer (5), nut (11) and socket (14) to pull the swaging tool from the installed sleeve.

a. Install reaction sleeve (15 or 22) and plate (16) over the threaded stem of swage assembly (6).

b. Put 5P-3931 Anti-Seize Compound or 6V-4876 Molykote Paste Lubricant on the threaded stem of swage assembly (6).

c. Position thrust bearing (13) on plate (16).

d. Put washer (5) on thrust bearing (13).

e. Install nut (11) on the threaded stem of swage assembly (6).

f. Use deep socket (14) and a 1/2 inch square drive impact wrench (or a 1/2 inch square drive ratchet wrench) to pull the swage assembly from the cylinder head.

g. Wipe away any excess lubricant or retaining compound that may be in the injector bore, within the injector sleeve.

h. Wipe away any excess retaining compound from swage assembly (6).

(A) Injector sleeve. (26) Roller expander.

18. Put a coating of clean engine oil on roller expander (26). Make sure the rollers are completely covered with oil.

19. Pull the mandrel out of roller expander (26) as far as possible. While holding the mandrel out, insert roller expander (26) all the way into the injector sleeve.

20. Install 1U-7845 Socket (35), or equivalent, on 4C-6936 Torque Wrench or equivalent. Put the torque wrench with socket (35) on the hex portion of the roller expander mandrel. Turn the torque wrench in a clockwise (CW) direction until a torque of 11 N·m (100 lb in or 8.0 lb ft) is achieved, or the turning torque stops increasing.

NOTE: A click-type 4C-6936 Torque Wrench is more convenient to use for the operation in Step 20, although a dial-type torque wrench is acceptable. If a dial-type 9S-7354 Torque Wrench is to be used, set the dial for 11 N·m (100 lb in).

21. When the specified torque is reached, or the turning torque stops increasing, stop turning the roller expander in the clockwise (CW) direction. Now turn the roller expander in the counterclockwise (CCW) direction until it is loose inside the injector sleeve.

22. Remove roller expander (26) from injector sleeve (A).

23. Clean the roller expander, especially the rollers, to remove any traces of retaining compound, that may have come from the injector sleeve.

NOTE: When the use of roller expander (26) is completed, clean it thoroughly using either 1U-8803 Cleaner Concentrate or 4C-4079 Component Cleaner. After cleaning, put a coat of either 1U-8265 Penetrating Oil or 1U-8809 Rust Preventive on the roller expander, then put store in tool case.

24. Wipe away any excess lubricant or retaining compound that may be in either the injector bore or in the injector sleeve.

25. Install previously selected guide bushing (19 or 20) into the cylinder head injector bore.

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NOTICE

Guide bushing (19 or 20) must be used to make sure the reamer is properly centered in the hole and to prevent cutting the injector sleeve too deeply. If the reaming procedure is not done correctly, the injector sleeve must be removed and replaced.

(9) Reamer assembly. (19 or 20) Guide bushing.

26. Apply a generous amount of clean grease to the cutting area of reamer assembly (9). This will not only lubricate the reamer assembly, but it will help to retain the cutting chips from the reaming process and keep them from falling down on top of the piston.

27. Insert reamer assembly (10) into guide bushing (13).

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NOTICE

For correct sealing of combustion gas, the injector seat must be free of machining chatter and scratches.

28. Using a 1U-7153 Speed Handle, with light, but even, pressure, turn reamer assembly (9) in the clockwise (CW) direction. (The reamer assembly will cut aggressively.)

Check cutting progress often. Stop cutting when the injector seat is full faced or when the shoulder of reamer assembly (9) comes in contact with the guide bushing.

If the injector seat does not machine to a 360 degree full face as required, the injector sleeve must be removed. Install another new injector sleeve and repeat the reaming procedure.

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NOTICE

Do not resharpen the reamer head of reamer assembly (9). If the reamer becomes dull, order a replacement 4C-5564 Reamer Head. The reamer head is precision machined and resharpening will cause an improperly reamed injector seat. This will result in combustion gas leaks between the injector and injector sleeve.

29. Remove any lubricants (grease) or copper particles that may be in or on the injector sleeve. Be sure to thoroughly clean the cylinder head fuel gallery.

30. Turn the engine crankshaft to put the piston back to the top center (TC) position. Remove the O-ring seals that were installed on the valve stems.

31. Reinstall the valve springs, retainers, and locks, if removed. Make adjustments as necessary. Install the unit injector(s).

32. Install all other parts that were removed from the engine. Make any adjustments that may be necessary.

Refer to the Service Manual for the injector and rocker arm assembly installation procedure. Also follow the fuel system testing and adjusting procedures.

Removing Upper Portion of Injector Sleeve

Use the following procedure if the threads in the upper portion of injector (A) were stripped during the removal procedure. This would result in removing only the lower portion of injector sleeve (A) while the upper portion remains in the cylinder head.

(A) Injector sleeve. (21) Driver. (7) Stud. (19 or 20) Guide bushing. (24) Sleeve driver.

1. Install sleeve driver (24) into injector bore.

2. Install previously selected guide bushing (19 or 20).

3. Install driver (21).

4. Use a hammer to drive the upper portion of the injector sleeve (A) free from the bore into the cylinder head.

NOTE: The last two or three hammer blows should only be hard enough to make sure that the upper portion of the injector sleeve (A) is free from the bore of the cylinder head.

(A) Injector sleeve. (5) Washer. (6) Nut. (7) Stud. (13) Thrust bearing. (14) Socket. (15 or 22) Reaction sleeve. (16) Plate. (24) Sleeve driver.

5. Center sleeve driver (24) in the bore of the cylinder head.

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NOTICE

Failure to center the sleeve driver may result in damage to cylinder head or the tooling.

6. Install reaction sleeve (15 or 22) and plate (16).

7. Put 5P-3931 Anti-Seize Compound or 6V-4876 Molykote Paste Lubricant on threaded stud (7).

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NOTICE

Failure to use 5P-3931 Anti-Seize Compound or 6V-4876 Molykote Paste Lubricant may cause damage to the threads of nut (11) and threaded stud (7).

8. Position thrust bearing (13) on plate (16).

9. Put washer (5) on thrust bearing (13).

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NOTICE

Failure to use washer (5) may damage thrust bearing (13).

10. Install nut (11) on threaded stud (7).

11. Use deep socket (14) and a 1/2 inch square drive impact wrench, 8H-8557 Ratchet Wrench, or equivalent, to pull sleeve driver (24) from the cylinder head.

12. Collapse the remaining portion of the injector sleeve with a punch and remove it from the cylinder head. Be careful not to push the upper portion of injector sleeve (A) into the coolant passage of the cylinder head.

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NOTICE

To prevent engine damage, remove all cutting chips and debris from the cylinder head fuel gallery and coolant passages. Use a cotton swab, lightly coated with grease, to aid in the removal of any particles.

13. Make sure all pieces of the injector sleeve have been removed before installing a new injector sleeve.

Parts and Service Repair Information

Specific repair service is not offered for this tool group. Components of the tool group are available from the Caterpillar Parts Department, should replacement parts be needed.

If problems or questions arise regarding the use of this tool group, contact the Caterpillar Service Technology Group at one of the following telephone numbers, or, if written communication is desired, use the mailing address given.