Using the 143-2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126 Engines{0374, 0599, 0701, 0706, 0781} Caterpillar

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Introduction

Important Safety Information

Illustration 1	g02139237
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Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.

Maintenance Section

The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal

Service Parts Section

The Service Parts section is a reference for parts identification and available part numbers.

Safety Icon Nomenclature

Personal Protection/Important Information

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Personal Protection/Important Information

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Crushing hazard (foot)

Crushing hazard (hand)

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General Information

Introduction

The 143-2099 Sleeve Replacement Tool Group 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 former 127-3458 Sleeve Replacement Tool Group can be converted to the new 143-2099 Sleeve Replacement Tool Group by adding the 143-2098 Sleeve Removal Tool Group . A complete list of the tools in the 143-2099 Sleeve Replacement Tool Group is listed in this Tool Operating Manual. Any tools not listed in this group can be discarded.

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 143-2099 Sleeve Replacement Tool Group and the information given in this Tool Operation Manual to perform the removal and installation procedure.

Additional Contact Information

For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:

Tool Group Components

Note: The installation on the following page provides a view of the specific tools. This provides a visual aid for tool identification. Individual tool part numbers are given in the table for each tool group.

Illustration 3	g02837598
143-2099 Sleeve Replacement Tool Group Refer to 143-2099 Sleeve Replacement Tool Group Table 1 for item identification.

Illustration 4	g02837617
Placement of tools in 143-2099 Sleeve Replacement Tool Group Refer to 143-2099 Sleeve Replacement Tool Group Table 1 for item identification. (AA) Remove the bottom piece of foam insert from this section (B) Make a cut (slit) in the foam at this location (C) Make a cut (slit) in the foam at this location

Note: For placement of the tools in the 143-2098 Sleeve Removal (update) Tool Group , use Figure 4 for the suggested location of each tool in the 127-3462 Box . The item numbers in Figure 4 correspond to the item numbers in Table 1. After the new tools are put into the existing box, place the new NEEG2748 Decal over the existing decal on the lid.

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 Guide Bushings and 4C-8715 Guide Bushings can be reworked. Grind the head of the bushing to dimension (A), shown in Figure 5.

Illustration 5	g02837618
Dimension (A) is 41.3 mm (1.63 inch)

Injector Sleeve Removal

These instructions apply with the cylinder head off, or on, the engine. However, with these tools and procedures, there should be no need to remove the cylinder head only to replace injector sleeves. The sleeves can be replaced after removal of the rocker arm assembly. Removing the valves or valve springs, or the inlet manifold, is not necessary.

Note: A special caution when using these tools in a training class. Proper tool function relies on a close fit between the swage tool and the injector bore in the cylinder head. If the bore has been significantly damaged, enlarged, or otherwise altered due to repeated use in training classes that print specifications would not be met, there could be difficulty in using the swage tool. In this case, a different cylinder head should be used.

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

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Illustration 6	g02837619
142-8279 Sleeve Puller (12)

2. Place 142-8279 Sleeve Puller (12) into injector sleeve, with the stud centered in the bore.

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Illustration 7	g02837620
142-8278 Swage Tool (11)

3. Apply 1P-0808 General Purpose Grease (or equivalent) to the countersink surface of 142-8278 Swage Tool (11). Place the 142-8279 Sleeve Puller (12) in the injector bore. Turn, and wiggle the swage tool from side to side in the bore. This will ensure that the tool is as low as it can go in the bore. When properly positioned, the swage tool will fit snugly in the bore, with very little side play possible. The bottom of the swage tool groove should be about 5 mm (0.2 inch) above the cylinder head surface.

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NOTICE
It is important that the sharp edge of the swage tool rests directly on the top of the injector sleeve, and not above the sleeve on the iron lip in the head. Damage to the head and tool may result if the tool is not properly seated prior to swaging.

Note: Extreme care must be taken to maintain the circular shape and sharp edge on the 142-8278 Swage Tool . Denting or dulling this edge can cause the tool to collapse the sleeve into the water jacket instead of swaging it. The tool should not be dropped, or impacted by other tools. When stored in the case, the 142-8279 Sleeve Puller should be inserted into the swage tool, and the protective device placed over the end. If the sharp edge becomes damaged or dull, do not attempt to sharpen the edge by using a file or other abrasive tools on the outside diameter. Serviceability of the tool may be restored by grinding or turning the 45 degree countersink surface. When performing this operation, the smooth surface finish of the countersink must be maintained.

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Illustration 8	g02837621
Install the 142-8281 Plate (A) M8 Bolt (14) 142-8281 Plate (18) 0S-1584 Hex Bolt (19) 6V-3821 Hex Bolt Jam Nuts (29) are not shown in this picture

4. On HEUI engines, remove the M8 bolts (A) which are closest to the valve springs from the inlet manifold, on those cylinders where the sleeve is to be removed. Bolt (A) shown in Figure 8 shows the location of the bolt to be removed, not the actual bolt that was removed.

5. Screw the two 1B-4430 Jam Nuts (29), Figure 10, all the way onto the 3L-2415 Bolt (18). Apply 5P-3931 Anti-Seize Compound or 6V-4876 Molykote Paste Lube to the exposed threads and screw it into 142-8281 Plate (14) .

6. Put three 6V-3821 Bolts (19) through plate (14), from the side marked "TOP" and thread them into the cylinder head. ON HEUI engines, the bolt on the top of the triangular shaped plate goes through the manifold bolt hole into the cylinder head. All the M8 bolts should be threaded into the head the same distance. The plate is as close as possible to parallel to the cylinder head surface. The 3L-2415 Bolt (18) should now be centered over the swage tool.

7. Thread bolt (18) through the plate onto the top of the swage tool until the assembly is hand tight, no slack. Locate jam nuts (29) with a gap of approximately 5.5 mm (0.22 inch) from the bottom surface of the nut to the top of the plate. This provides a fixed travel distance for the swage tool and helps prevent pushing the swage tool too deeply into the cylinder head. Once the jam nuts are in place, tighten them against each other.

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Illustration 9	g02837622
Tightening bolt (18) Jam nuts (29) are not shown, but are required

8. Use a 3/4 inch socket and ratchet, or an adjustable wrench, to tighten bolt (18) approximately 5.5 mm (0.22 inch), as shown in Figure 9. Jam nuts are not shown, but are required. This forces swage tool (11) down, swaging the top of the injector sleeve around the disk of the sleeve puller. A high torque will be noticed at the beginning when swaging is started. It should then become easier, until the mass of swaged brass causes torque to increase again. Depending on the type and amount of grease used, the changes in torque may not be readily apparent. The use of power tools in this operation is not recommended. When completed, the bottom of the swage tool groove should be close to the surface of the head.

   Note: Driving the swage tool down too far can cause the sleeve to collapse below the upper bore in the cylinder head, making it more difficult to remove.

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Illustration 10	g02837624
Injector Sleeve is Swaged Over Sleeve Puller (12) (11) Swage Tool (12) Sleeve Puller (14) Plate (18) Bolt (29) Jam Nuts

9. Unscrew bolt (18), remove three bolts (19), plate (14), and swage tool (11) .

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Illustration 11	g02837625
Injector Sleeve is Swaged Inward Ready for Removal

10. Check the swage of the injector sleeve, as shown in Figure 11. The brass should be evenly swaged with a 6.4 mm (0.25 inch) gap around the sleeve puller stud. If the swage appears to be incomplete, reassemble the swaging procedure, by moving the two jam nuts an additional 2 mm (0.08 inch). if the swage is forced too deep, the sleeve may expand into the water passage in the head, making it difficult or impossible to pull the sleeve out through the bore. Once the swage is complete, remove the hardware.

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Illustration 12	g02837627
142-8280 Sleeve Stud (13)

11. Thread the 142-8280 Sleeve Stud (13) onto the 142-8279 Sleeve Puller .

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Illustration 13	g02837628
Removing Injector (6) 125-7059 Reaction Sleeve , HEUI (7) 9U-5671 Reaction Sleeve , MUI (8) 4C-5572 Plate (16) 1F-7958 Nut (17) 7D-1649 Hard Washer

12. Center either the 9U-5671 MUI Reaction Sleeve (7) or 125-7059 HEUI Reaction Sleeve (6) over the sleeve bore with the stud extending through the top. Apply 5P-3931 Anti-Seize Compound or 6V-4876 Molykote Paste Lube to the threads of the stud.

    Note: It is very important to make sure that the sleeve puller and sleeve stud assembly are centered within the injector bore. Failure to do so can cause the sleeve to bind inside the bore during the pulling operation.

13. Put 4C-5572 Plate (8), 7D-1649 Washer (17), and 1F-7958 Nut (16) on the stud, as shown in Figure 13. Use a 3/4 inch deep well socket and ratchet or an adjustable wrench to tighten the nut and pull the sleeve from the injector bore.

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Illustration 14	g02837629
Injector Sleeve Removed From Cylinder Head

14. Disassemble the removal tools down to the sleeve puller and the sleeve. Clamp the sleeve in a vise with the sleeve puller ring resting as low as it will go on the sleeve chamfer. This allows extra room for cutting the sleeve free from the sleeve puller.

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Illustration 15	g02837630
Remove Injector Sleeve From Sleeve Puller

15. Use a pair of side cutters, as shown in Figure 15, to cut through the brass down to sleeve puller ring diameter, and then to pry the brass outward. Continue until the sleeve puller can be pulled out of the sleeve.

    Note: Because of the sharp edges of the sleeve, produced when removing excess material with the side cutters, wearing gloves during this operation is highly recommended. An alternate removal method is to clamp the sleeve/puller assembly in the vise sideways with the nozzle end out. Use a hacksaw to cut off the small end of the sleeve, below the disk.

16. Thoroughly clean the injector sleeve bore.

Injector Sleeve Installation

Illustration 16	g02837631
(3) or (4) Guide Bushing (10) Reamer Group

1. Select a guide bushing (3) or (4) that best fits into the cylinder head injector bore above the injector sleeve that is to be removed.

   Use large guide bushing (3) 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 (4) .

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 (3) or (4) and reamer group (10) .

   1. 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 3.b.

   2. Use a 4C-9929 Electric Drill or 4C-9928 Cordless Drill (if electricity is not available) with reamer group (10) 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 that the hole is the correct size. The hole is used as a pilot for the small end of swage assembly (5) during injector sleeve installation. It is also used for the pilot of reamer (2) during injector seat reaming.

4. Remove reamer group (10) and guide bushing (3) or (4) from cylinder head.

5. Use a 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 (21) with an electric drill to clean the injector sleeve bores in the cylinder head. If necessary, use a small pick and/or emery clutch 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 (20 ) and (22) can be used with an electric drill to clean the small bore at the bottom of the cylinder block. If either brush does not reach the bottom bore, use a 9U-7237 Drill Extension .

   Note: Sleeve cleaning brush (20) 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.

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Illustration 17	g02837633
(A) Injector sleeve (B) Locations to coat with 7M-7454 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) .

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

    2. Make sure that 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.

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Illustration 18	g02837634
(A) Injector Sleeve (1) Driver (3) or (4) Guide Bushing (5) Swage Assembly

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

14. Put swage assembly (5) 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 (3) or (4) over the shank of swage assembly (5) .

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Illustration 19	g02837635
(A) Injector Sleeve (1) Driver (3) or (4) Guide Bushing (5) Swage Assembly

16. Position a 125-7060 Driver (1), Figure 18, or a 143-8612 Driver over swage assembly (5) .

    To drive the swage down through the sleeve, use either a 125-7060 Driver (1), Figure 18, or a 143-8612 Driver may also be used. Use 125-7060 Driver if the head is off the engine, or if there is sufficient room to swing a hammer. If the clearance is very limited, use the 143-8612 Driver .

    Using 125-7060 Driver

    Use a 1 to 2 kg (2.2 to 4.4 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. 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.

    Using 143-8612 Driver

    Remove the 4C-5548 Stud from the swage tool.

    Thread the 3L-2415 Bolt into the 142-8281 Plate and secure the plate onto the cylinder head using three 7X-2539 Bolts .

    Use a 3/4 inch socket and ratchet to force the swage tool down into the sleeve. Use a piece of paper as a feeler gauge between the driver and guide bushing to determine when the swage tool is at its completed depth.

    When the swage process is complete, remove the tooling and reinstall the 4C-5548 Stud in the swage tool.

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Illustration 20	g02837636
(5) Swage Assembly (6) or (7) Reaction Sleeve (8) Plate (25) Socket (26) Nut (27) Thrust Bearing (28) Washer

17. Use reaction sleeve (6) or (7), plate (8), thrust bearing (27), washer (28), nut (26), and socket (25) to pull the swaging tool from the installed sleeve.

    1. Install reaction sleeve (6) or (7) and plate (8) over the threaded stem of swage assembly (5) .

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

    3. Position thrust bearing (27) on plate (8) .

    4. Put washer (28) on thrust bearing (27) .

    5. Install nut (26) on the threaded stem of swage assembly (5) .

    6. Use a deep socket (25) and a 1/2 inch square drive impact wrench, or a 1/2 inch square drive ratchet wrench, to pull swage assembly from the cylinder head.

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

    8. Wipe away any excess retaining compound from swage assembly (5) .

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Illustration 21	g02837637
(A) Injector sleeve (9) Roller expander

18. Put a coating of clean engine oil on roller expander (9). Make sure that the rollers are completely covered with oil.

19. Pull the mandrel out of roller expander (9), as far as possible. While holding the mandrel out, insert roller expander (9) all the way into injector sleeve.

20. Install 214-6625 Socket (24) or equivalent on a 4C-6936 Torque Wrench or equivalent. Put the torque wrench with socket (24) 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 (97.4 lb in) 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 9S-7354 Torque Wrench is to be used, set the dial for 11 N·m (97.4 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 (9) from injector sleeve (A) .

23. Clean 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 (9) 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 Preventative on the roller expander. 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 (3) or (4) into the cylinder head injector bore.

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NOTICE
Guide bushing (3) or (4) must be used to make sure that 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.

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Illustration 22	g02837638
(2) Reamer Assembly (3) or (4) Guide Bushing

26. Apply a generous amount of clean grease to the cutting area of reamer assembly (2). This will not only lubricate the reamer assembly, but it will help to retain the cutting chips from the reaming process. Cutting chips will be kept from falling on top of the piston.

27. Insert reamer assembly (2) into guide bushing (3) or (4) .

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NOTICE
For correct sealing of combustion gas, the injector seat must be free of machining chatter and scratches, including vertical lines left by the reamer at the end of the cut.

28. Using a 1U-7153 Speed Handle , with light, but even pressure, turn reamer assembly (2) in the clockwise (CW) direction. The reamer assembly will cut aggressively. If there is an obstruction directly over the hole, use a 6V-0094 Universal Joint in the reamer assembly.

    Check cutting progress often. Stop cutting when the injector seat is full faced or when the shoulder of reamer assembly (2) 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.

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

    Note: To prevent reaming the sleeve too deep, 0.25 mm (0.01 inch) shim stock can be cut into washer shapes and used between the reamer assembly and guide bushing to provide a positive stop during the operation. Remove only the number of shims required to achieve cleanup of the injector seat, as described above.

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NOTICE
Do not resharpen the reamer head of reamer assembly (2). 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. A new solid-carbide 131-8362 Reamer Head is also available providing 3 to 5 times the cutting life of the 4C-5564 Reamer Head .

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 injectors.

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.

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.

For additional product support questions concerning this tool, contact the Caterpillar Dealer Service Tools Hotline.