Usage:
Introduction
The 9U-6860 Tool Group is available for the replacement of the unit injector sleeves in the cylinder head of the 3176 and 3176B engines.
The injector sleeves are swaged into the cylinder head at the time of assembly. If it becomes necessary to replace any of these injector sleeves, use 9U-6860 Tool Group and the information given in this Special Instruction in order to perform the removal and installation procedure.
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Do not perform any procedure outlined in this publication or order any parts until you read and understand this information. |
Reference: Service Manual.
Tool Group Components
NOTE: The illustration that follows provides a view of the specific tools to aid in tool identification. Individual tool part numbers are given in the charts of the tool group parts.
9U-6860 Tool Group For Sleeve Replacement
The following are additional tools and supplies that allow easier completion of the procedures.
4C-6730 Roller Expander Components
Illustration 1: Components of 4C-6730 Roller Expander.
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. Valves, valve springs, and bridge guides may be removed from the specific cylinder(s); however, it is not necessary.
2. Remove any loose material or deposits from inside the injector sleeve.
Illustration 2: (1) Nut. (2) Hard washer. (3) Lower pilot. (5) Tap. (15) Guide bushing. (21) Socket. (A) Injector sleeve.
3. Insert lower pilot (3) into sleeve (A). Then loosely install hard washer (2) and nut (1) at the bottom side of the cylinder head.
4. Select a guide bushing (15) that best fits into the cylinder head injector bore; above the sleeve that is to be removed.
NOTE: The two 4C-8720 and 4C-8721 Guide Bushings supplied with the group are similar in appearance. However, they have slightly different outside diameters. Both should fit into the injector bore in the cylinder head due to tolerance variations in the bore. Use the guide bushing that fits the tightest (with hand force) into the injector bore of a given cylinder. This guide bushing should then be the only one used on this cylinder for further operations that require a guide bushing.
Remove the guide bushing from the cylinder head.
5. Install tap (5) in injector sleeve (A). Place the pilot bore end of the tap over the pilot of lower pilot (3). Use clean engine oil, or cutting oil, to lubricate the injector sleeve and the cutting threads of tap (5).
6. Install previously selected guide bushing (15) over the shank of tap (5) and into the cylinder head injector bore.
7. Tighten nut (1) on lower pilot (3). This will prevent the injector sleeve from turning during the thread cutting procedure.
8. Place socket (21) on tap (5). Use a 1/2 in drive ratchet wrench to drive tap (5).
9. Cut threads in the injector sleeve by turning the tap in a clockwise (CW) direction, until the tap contacts the top surface of lower pilot (3).
If the sleeve turns, use the roller expander to tighten the sleeve into the head.
10. Remove tap (5) and guide bushing (15). Thoroughly clean any debris from the newly cut threads.
11. Remove nut (1) and hard washer (2).
Illustration 3: (3) Lower pilot. (6) Puller screw. (16) Socket. (17) Bridge plate. (18) Bolt. (20) Hard washer. (22) Thrust bearing. (23) Full nut. (25) Puller stud.
12. Install puller assembly (6 and 25) into the injector sleeve until the puller stud contacts lower pilot (3). Then retract the puller screw (6) 1/4 turn.
13. Install bridge plate (17) with support bolts (18) over puller stud (25).
15. Position thrust bearing (22) on puller stud (25).
16. Place hard washer (20) on thrust bearing (22).
17. Install full nut (23) on puller stud (25).
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Check that the nut and washer have been removed from the lower pilot (3). |
18. Use socket (16) and a 1/2 in drive impact wrench (or a 1/2 in drive ratchet wrench) to pull the injector sleeve from the cylinder head.
The puller assembly and the injection sleeve can be lifted out of the cylinder head when the injection sleeve has been pulled free of its bore.
19. Remove full nut (23), hard washer (20), thrust bearing (22), and the bridge plate (17) with bolts.
20. Loosen and remove the injector sleeve from puller screw (6). If the injector sleeve can not be removed by hand, use release block (19) as follows:
- * Position release block (19) in a vise. Tighten the vise just enough to retain the release block.
- * Place the threaded (stem) end of lower pilot (3) into release block (19). Then install nut (1) with hard washer (2) to retain the sleeve in release block (19).
- * Use an adjustable wrench to remove puller screw (6) from the injector sleeve.
- * Place the threaded (stem) end of lower pilot (3) into release block (19). Then install nut (1) with hard washer (2) to retain the sleeve in release block (19).
Injector Sleeve Installation With Cylinder Head Off The Engine
1. Use pick set (24) and/or emery cloth to clean the injector sleeve bores in the cylinder head. If necessary, use large bore brush (12) with an electric drill to remove any remaining particles of copper or retaining compound. Component cleaner can be used to soften the retaining compound in the grooves.
Illustration 4: (38) Use the pick set to completely remove any brass ring material remaining in the grooves after the sleeve has been removed. (39) Inset showing grooved area. (40) Typical injector sleeve bores in 104-3844 Cylinder Head.
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Remove all cutting chips and debris from the cylinder head fuel gallery. The 4C-4774 Vacuum Gun (operated by compressed air) is useful for this purpose. A cotton swab, lightly coated with grease, will also aid in the removal of any particles. |
2. Small bore brush (27) can be used with an electric drill to clean the small bore at the bottom.
NOTE: Small tapered brush (26) is used to clean the inside of an injector sleeve during injector replacement.
3. Use 8T-4011 Solvent Cleaner to spray the inside of each injector sleeve bore in the cylinder head and the outside of each injector sleeve. Permit the cleaner to become thoroughly dry.
4. 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 thoroughly dry.
Illustration 5: (B) Locations to coat with 7M-7456 Bearing Mount or Loctite® 609.
5. Apply a coat of 7M-7456 Bearing Mount or Loctite® 609 to the injector sleeve bore in the cylinder head and to the outside of the new injector sleeve at locations (B). DO NOT apply to the inside of the sleeve.
Illustration 6: (A) Injector sleeve. (3) Lower pilot. (36) Pipe or tubing.
6. Place new injector sleeve (A) into its bore in the cylinder head. Wipe away any excess retaining compound that is either in or above the injector sleeve.
7. Install lower pilot (3) into the injector sleeve. To avoid damage to the guide on lower pilot (3), use a piece of pipe or tubing (36) with a small hammer to LIGHTLY tap on the lower pilot. This will ensure that the new injector sleeve is fully seated in the cylinder head.
Remove lower pilot (3).
Illustration 7: (14) Roller expander. (32) Mandrel.
8. Place a coating of clean engine oil on 4C-6730 Roller Expander (14). Ensure the rollers are completely covered with oil.
9. Pull and hold mandrel (32) out of the roller expander (14) as far as possible. Then completely insert the roller expander into the injector sleeve.
10. Place a torque wrench with 11 mm socket on the hex portion of 4C-6730 Roller Expander mandrel. Turn the torque wrench in a clockwise (CW) direction in order to achieve a torque of 11 N·m (100 lb in).
NOTE: If torque stops increasing before 11 N·m (100 lb in) the sleeve is not hard enough or the bore is oversized in the head. START OVER.
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To ensure that accurate torque is achieved, a calibrated 4 4C-6936 Torque Wrench or equivalent is required. |
11. When the specified torque is reached, stop turning the roller expander in the clockwise (CW) direction. Now turn the roller expander in the counterclockwise (CCW) direction until it is loose in the injector sleeve.
Remove 4C-6730 Roller Expander from the injector sleeve.
12. Wipe the roller expander, especially the rollers, to remove any traces of 7M-7456 Bearing Mount or Loctite® 609 that may have come from the injector sleeve.
NOTE: When usage of 4C-6730 Roller Expander is completed, clean it thoroughly using either 1U-8803 Cleaner Concentrate or 8T-9011 Component Cleaner. After the cleaning, place a generous coat of either 1U-8265 Penetrating Oil or 1U-8809 Rust Preventive on the roller expander. When finished, place it in its storage case.
Illustration 8: (A) Injector sleeve. (13) Driver. (15) Guide bushing. Swage/flaring assembly: (8) Set screw. (9) Bottom swage. (11) Flare tool.
14. Slide the same guide bushing (15) used previously onto 9U-6856 Flare Tool (11).
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Some 9U-6856 Flare Tools have their part number stamped on the turn which fits into the guide bushing. This arrangement interferes with the fit. Before the first tool use, the part number should be filed down as necessary in order to permit fit of the flare tool in the guide bushing. |
15. Use 5P-3931 Anti-seize Compound, 6V-4876 Molykote Paste Lubricant, or grease to lubricate the swage/flaring assembly. Place it into the sleeve with the flare tool prying notch facing either opening between the valve springs. This will allow access for removal of the swage/flaring assembly.
17. Use a hammer to drive down the swage/flaring assembly until driver (13) contacts guide bushing (15). This will provide the correct depth. Remove the driver.
Illustration 9: Pinch bar prying the swage/flaring assembly out of the sleeve. Bridge plate assembly with washer and bolts.
18. Using 5F-4764 Pinch Bar with miscellaneous spacing material, pry the swage/flaring assembly out of the sleeve. If a prying notch accessibility problem occurs, the swage/flaring assembly may be removed using OL-1143 Bolt (3/8-16 × 2.5 in length) and 7X-0613 Hard Washer with the bridge plate assembly. Place the bolt with washer through the bridge plate. Tighten it into the flare tool. Use an adjustable wrench on the flats of the flare tool in order to prevent it from turning in the sleeve.
19. Install previously selected guide bushing (15) into the bore.
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The guide bushing MUST be used to ensure the reamer is properly centered in the hole. It is also used to prevent cutting the injector sleeve too deeply. If the reaming procedure is not correctly performed, the injector sleeve must be removed and replaced. |
Illustration 10: (4) Tee handle. (7) Reamer shank. (8) Set screw. (10) Reamer head. (15) Guide bushing.
21. Use a generous amount of clean grease to lubricate the cutting area of the reamer assembly. Insert the reamer assembly into guide bushing (15).
22. The reamer assembly may be turned with 4C-9495 Tee Handle (4); however, 1U-7153 Speed Handle can also be used.
With light but even pressure, turn the reamer assembly in a 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 360° full face, the injector sleeve must be removed. Install another injector sleeve and perform the reaming procedure again.
NOTE: It is best to stop cutting immediately when the seat is full face, so only the minimum amount of material is removed. This will help by retaining as much material as possible in the event that a future reaming procedure is necessary.
23. Check the seat by applying toolmakers ink to the sleeve seat. Then, install an injector without O-rings. Turn the clamp to 29 N·m (22 lb ft). Remove the injector and inspect it for a 360 degree full seat pattern. If not complete, continue reaming.
NOTE: Use toolmakers ink to check the seat any time a new sleeve has been installed or whenever a combustion leak is evident in an existing sleeve.
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Do not resharpen reamer head (10) of reamer assembly. If the reamer becomes dull, order replacement 4C-5538 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 the injector sleeve. |
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For correct sealing of combustion gas the injector seat must be free of machining chatter and scratches including vertical lines left by the reamer teeth at the end of the cut. |
24. Remove any evidence of lubricants or copper particles that may be either in, or on, the injector sleeve. Thoroughly clean the cylinder head fuel galleries.
Injector Sleeve Removal With Cylinder Head On The Engine
NOTE: This procedure is applicable only if there is adequate clearance above the engine. In some applications, removal of the cylinder head may be required due to space limitations.
NOTE: Prior to removal of the sleeve, verify that the coolant is drained below the head level.
1. Turn the engine crankshaft to place the piston at top center (TC) for the cylinder whose injector sleeve is being replaced. Piston position can be determined through the unit injector bore after the unit injector is removed.
2. Valve springs and bridge guides may be removed from the specific cylinder(s); however, it is not necessary.
3. If the valve springs are removed, install 2J-6274 O-ring Seal on the valve stem of each of the valves for the affected cylinder.
With the valves UP, in the CLOSED position, push an O-ring Seal down the stem of each valve until it contacts 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.
4. Rotate the crankshaft to lower the piston approximately 51 mm (2.0 in). (This dimension can be measured through the unit injector bore.) With the piston in this position, it will not interfere with installation of lower pilot (3).
5. Remove any loose material or deposits from inside the injector sleeve that would prevent lower pilot (3) from seating squarely in the sleeve.
6. Apply a coat of grease to the inside bottom part of the injector sleeve. This will aid in preventing copper chips from falling through the injector sleeve and collecting on top of the piston.
7. Select a guide bushing (15) that best fits into the cylinder head injector bore; above the sleeve that is to be removed.
NOTE: The two 4C-8720 and 4C-8721 Guide Bushings supplied with the group are similar in appearance. However, they have slightly different outside diameters. Both should fit into the injector bore in the cylinder head due to tolerance variations in the bore. Use the guide bushing that fits the tightest (with hand force) into the injector bore of a given cylinder. This guide bushing should then be the only one used on this cylinder for further operations that require a guide bushing.
DO NOT leave guide bushing (15) installed in the cylinder head at this time.
Illustration 11: (3) Lower pilot. (5) Tap. (15) Guide bushing. (21) Socket. (A) Injector sleeve.
8. Insert lower pilot (3) into the injector sleeve.
9. Place tap (5) into the injector sleeve. Place the pilot end of the tap into the pilot bore of lower pilot (3). Use clean engine oil, or cutting oil, to lubricate the injector sleeve and the cutting threads of tap (5).
10. Install previously selected guide bushing (15) over the pilot diameter of the cutting tool and into the injector bore in the cylinder head.
11. Place socket (21) on tap (5). Use a 1/2 in drive ratchet wrench to drive tap (5).
12. Cut threads in the injector sleeve by turning the tap in a clockwise (CW) direction until the tap contacts with the top surface of lower pilot (3).
If the sleeve turns, use one of the following two methods to tighten the sleeve:
- * Remove the pilot and tighten the sleeve using 4C-6730 Roller Expander.
- * Use an impact wrench in quick bursts on the tap. This may wedge the sleeve in the head so the threading process can continue.
NOTE: The second method may shorten the tap life but it is more economical than removing the head.
NOTE: If the sleeve still turns in its bore during this procedure, it will be necessary to remove the cylinder head from the engine. It will also be necessary to remove the injector sleeve according to the procedure given in the topic entitled "Injector Sleeve Removal With Cylinder Head Off The Engine".
13. Carefully remove tap (5) and guide bushing (15) in order to prevent cutting chips from falling through the hole in the injector sleeve and onto the top of the piston.
14. Wipe away all debris from both the newly cut threads and the injector sleeve.
Illustration 12: (3) Lower pilot. (6) Puller screw. (16) Socket. (17) Bridge plate. (18) Bolt. (20) Hard washer. (22) Thrust bearing. (23) Full nut. (25) Puller stud.
15. Install puller assembly (6 and 25) into the injector sleeve until puller screw (6) contacts lower pilot (3). Retract the puller screw 1/4 turn.
16. Install bridge plate (17) with support bolts (18) over puller stud (25).
18. Position thrust bearing (22) on puller stud (25).
19. Place hard washer (20) on thrust bearing (22).
20. Install full nut (23) on puller stud (25).
21. Use socket (16) and a 1/2 in drive impact wrench (or a 1/2 in drive ratchet wrench) to pull the injector sleeve from the cylinder head.
The puller assembly and the injection sleeve can be lifted out of the cylinder head when the injection sleeve has been pulled free of its bore.
22. Remove full nut (23), hard washer (20), thrust bearing (22), and bridge plate (17) with bolts.
23. Loosen and remove the injector sleeve from puller screw (6). If the injector sleeve can not be removed by hand, use release block (19) as follows:
- * Position release block (19) in a vise. Tighten the vise just enough to retain the release block.
- * Place the threaded (stem) end of lower pilot (3) into the release block (19). Then install nut (1) with hard washer (2) to retain the sleeve in release block (19).
- * Use an adjustable wrench to turn puller screw (6) and separate the tools from the injector sleeve.
- * Place the threaded (stem) end of lower pilot (3) into the release block (19). Then install nut (1) with hard washer (2) to retain the sleeve in release block (19).
Injector Sleeve Installation With Cylinder Head On The Engine
1. Use pick set (24) and/or emery cloth to clean the injector sleeve bores in the cylinder head. If necessary, use large bore brush (12) with an electric drill to remove any remaining particles of copper or retaining compound. Component cleaner can be used to soften the retaining compound in the grooves.
Illustration 13: (38) Use the pick set to completely remove any brass ring material in the grooves after the sleeve was removed. (39) Inset showing grooved area. (40) Typical injector sleeve bores in 104-3844 Cylinder Head.
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Remove all cutting chips and debris from the cylinder head fuel gallery. The 4C-4774 Vacuum Gun (operated by compressed air) is useful for this purpose. A cotton swab, lightly coated with grease, will also aid in the removal of any particles. |
2. Small bore brush (27) can be used with an electric drill to clean the small bore at the bottom.
NOTE: Small Tapered Brush (26) is used to clean the inside of an injector sleeve during unit injector replacement.
3. Use 8T-9011 Solvent Cleaner to spray the inside of each injector sleeve bore in the cylinder head and the outside of each injector sleeve. Allow the cleaner to become thoroughly dry.
4. 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 become thoroughly dry.
Illustration 14: (B) Locations to coat with 7M-7456 Bearing Mount or Loctite® 609.
5. Apply a coat of 7M-7456 Bearing Mount or Loctite® 609 to the injector sleeve bore in the cylinder head and to the outside of the new injector sleeve at locations (B). DO NOT apply it to the inside of the sleeve.
Illustration 15: (A) Injector sleeve. (3) Lower pilot. (36) Pipe or tubing.
6. Place new injector sleeve (A) into its bore in the cylinder head. Wipe away any excess retaining compound that is either in or above the injector sleeve.
7. Install lower pilot (3) into the injector sleeve. To avoid damage to the guide on the lower pilot (3), use a piece of pipe or tubing (36) with a small hammer to LIGHTLY tap the lower pilot. This will ensure that the new injector sleeve is fully seated in the cylinder head.
Remove lower pilot (3).
Illustration 16: (14) Roller expander. (32) Mandrel.
8. Place a coating of clean engine oil on 4C-6730 Roller Expander (14). Ensure the rollers are completely covered with oil.
9. Pull and hold mandrel (32) out of the roller expander (14) as far as possible. Then completely insert the roller expander into the injector sleeve.
10. Place a torque wrench with a 11 mm socket on the hex portion of 4C-6730 Roller Expander mandrel. Turn the torque wrench in a clockwise (CW) direction in order to achieve a torque of 11 N·m (100 lb in).
NOTE: If torque stops increasing before 11 N·m (100 lb in) the sleeve is not hard enough or the bore is oversized in the head.
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To ensure that accurate torque is achieved, a calibrated 4C-6936 Torque Wrench or equivalent is required. |
11. When the specified torque is reached, stop turning the roller expander in the clockwise (CW) direction. Now turn the roller expander in the counterclockwise (CCW) direction until it is loose in the injector sleeve.
Remove 4C-6730 Roller Expander from the injector sleeve.
12. Wipe the roller expander, especially the rollers, to remove any traces of 7M-7456 Bearing Mount or Loctite® 609 that may have built up from the injector sleeve.
NOTE: When usage of 4C-6730 Roller Expander is completed, clean it thoroughly using either 1U-8803 Cleaner Concentrate or 8T-9011 Component Cleaner. After the cleaning, place a generous coat of either 1U-8265 Penetrating Oil or 1U-8809 Rust Preventive on the roller expander. Place it in its storage case.
Illustration 17: (A) Injector sleeve. (13) Driver. (15) Guide bushing. Wage/flaring assembly: (8) Set screw. (9) Bottom swage. (11) Flare tool.
14. Slide same guide bushing (15) used previously onto 9U-6856 Flare Tool (11).
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Some 9U-6856 Flare Tools have their part number stamped on the turn which fits into the guide bushing. This arrangement interferes with the fit. Before the first tool use, the part number should be filed down as necessary in order to permit fit of the flare tool in the guide bushing. |
15. Use 5P-3931 Anti-seize Compound, 6V-4876 Molykote Paste Lubricant, or grease to lubricate the swage/flaring assembly. Place it into the sleeve with the flare tool prying notch facing either opening between the valve springs. This will allow access for removal of the swage/flaring assembly.
17. Use a hammer to drive down the swage/flaring assembly until driver (13) contacts guide bushing (15). This will provide the correct depth. Remove the driver.
Illustration 18: Pinch bar prying the swage/flaring assembly out of the sleeve. Bridge plate assembly with washer and bolts.
18. Using 5F-4764 Pinch Bar with miscellaneous spacing material, pry the swage/flaring assembly out of the sleeve. If a prying notch accessibility problem occurs, the swage/flaring assembly may be removed using 0L-1143 Bolt (3/8-16 × 2.5 in) and 7X-0613 Hard Washer with the bridge plate assembly. Place the bolt with washer through the bridge plate. Tighten it into the flare tool. Use an adjustable wrench on the flats of the flare tool in order to prevent it from turning in the sleeve.
Illustration 19: (4) Tee handle. (7) Reamer shank. (8) Set screw. (10) Reamer head. (15) Guide bushing.
19. Install previously selected guide bushing (15) into the bore.
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The guide bushing MUST be used to assure the reamer is properly centered in the hole. It also must be used to prevent cutting the injector sleeve too deeply. If the reaming procedure is not correctly performed, the injector sleeve must be removed and replaced. |
21. Use a generous amount of clean grease to lubricate the cutting area of the reamer assembly. Insert the reamer assembly into guide bushing (15).
22. The reamer assembly may be turned with 4C-9495 Tee Handle (4); however 1U-7153 Speed Handle will provide better control.
With light but even pressure, turn the reamer assembly in a 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 contacts with the guide bushing.
If the injector seat does not machine to 360° full face, the injector sleeve must be removed. Install another injector sleeve and again perform 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. This will retain as much material as possible in the event that a future reaming procedure is necessary.
Check the seat by applying toolmakers ink to the sleeve seat. Then, install an injector without O-rings. Turn the clamp to 29 N·m (22 lb ft). Remove injector and inspect for a 360 degree full seat pattern. If not complete, continue reaming.
NOTE: Use toolmakers ink to check the seat any time a new sleeve has been installed or whenever a combustion leak is evident in an existing sleeve.
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Do not resharpen reamer head (10) of the reamer assembly. If the reamer becomes dull, order replacement 4C-5538 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 the injector sleeve. |
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For correct sealing of combustion gas, the injector seat must be free of machining chatter and scratches, including vertical lines left by the reamer teeth at the end of the cut. |
23. Remove any evidence of lubricants or copper particles that may be either in, or on, the injector sleeve. Thoroughly clean the cylinder head fuel galleries.
24. Turn the engine crankshaft to place the piston back to the top center (TC) position. Remove the O-ring seals that were installed on the valve stems.
Install the valve springs and bridge guides, then perform adjustments as necessary. Install the unit injector(s).
25. Install all other parts that were removed from the engine. Perform any adjustments that may be necessary.
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. If written communication is desired, use one of the following mailing addresses.
Telephone-Toll Free Numbers
Outside Illinois 1-800-542-8665
Inside Illinois 1-800-541-8665
Canada 1-800-523-8665
Fax Number 1-309-675-6618
Outside of North America use Telex Number 404435.
Mailing address
U.S. Mail, United Parcel Service, and/or Emery:
Caterpillar Service Technology Group100 N.E. Adams Street
Peoria, IL 61629-9120