C15 and C18 On-Highway Engines Electronic Unit Injector - Remove and Install Caterpillar


Electronic Unit Injector - Remove and Install
`
C15 and C18 On-Highway Engines [UENR3300]
FUEL SYSTEM
PUMP GP-FUEL INJECTION
C15 and C18 On-Highway Engines Electronic Unit Injector - Remove and Install
1.1. Specifications
2.1. Removal Procedure
3.1. Installation Procedure

Specifications



Illustration 1g03363488
Typical example

Table 1
Specification for 381-6298 Fuel Injection Pump Gp and 372-6468 Fuel Injection Pump Gp 
Item  Qty  Part  Specification Description 
8S-9191 Bolt  Torque to 55 ± 10 N·m (41 ± 7 lb ft)
Before assembly, lubricate the O-ring seals and the bore with a 50 percent mix of green 8T-2998 Lubricant and clean engine oil. 

Removal Procedure

Table 2
Required Tools 
Tool  Part Number  Part Description  Qty 
5F-4764  Pry Bar 
8T-2998  Lubricant 
1U-5718  Vacuum Pump 
169-7372 Fluid Sampling Bottle 
4C-4057 Tube
7.9 mm (0.31 inch) OD 
4C-5552  Large Bore Brush 
8T-7765  Surface Reconditioning Pad 
N/A  Nyogel 760G 

Start By:

  1. Remove the rocker arms and the rocker arm shaft.


NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.

Dispose of all fluids according to local regulations and mandates.



NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.




    Illustration 2g01259747


    Illustration 3g06579272

  1. Remove valve bridges (1). Note the location and orientation of the valve bridges for installation purposes.

  2. Disconnect harness assembly (2).


    Illustration 4g01259759


    NOTICE

    If the injector hold down bolt is loose during the removal procedure, inspect the injector bore for wear and debris. Replace the clamp and spacer.


  3. Remove bolt (3) and spacer (4) from clamp (5).

  4. Place an identification mark on electronic unit injector (6) for installation purposes. Each electronic unit injector must be reinstalled in the original location in the cylinder head.


    Illustration 5g01259777

  5. Use Tooling (A) in bolt hole to pry clamp (5) and electronic unit injector (6) free from the cylinder head.

    Note: Improper use of Tooling (A) can damage the spring or the unit injector.

  6. Remove electronic unit injector (6) from the cylinder head.


    Illustration 6g01259809

  7. Remove O-ring seals (7) from electronic unit injector (6).

Installation Procedure


NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.


  1. Use Tooling (C) to remove the fuel and oil from the cylinder. Evacuate as much fuel and oil as possible from the cylinder before installing the electronic unit injector. Several evacuations may be necessary.

  2. Use Tooling (D) to clean the carbon deposit from inside the electronic unit injector sleeve.

  3. Use Tooling (E) to clean the carbon from the seat area that is inside the electronic unit injector sleeve.


    Illustration 7g01259809

  4. Install O-ring seals (7) on electronic unit injector (6). Lubricate the top two O-ring seals with a 50/50 mixture of clean engine oil and Tooling (B).


    Illustration 8g06493097

  5. Apply Tooling (F) to the four terminals of electronic unit injector (6).


    Illustration 9g01259759


    NOTICE

    When an electronic unit injector is replaced, the new electronic injector code must be programmed into the engine's personality module software by using the calibration menu on the Electronic Service Tool. If the new electronic injector code is not entered, the characteristics of the previous electronic unit injector is assumed.

    If it is not possible to immediately reprogram the electronic injector code into the personality module software, the engine will not be severely harmed. The new electronic injector code should be reprogrammed as quickly as possible in order to optimize engine performance.


  6. Install electronic unit injector (6) and clamp (5) into the original location in the cylinder head.

  7. Install spacer (4) and bolt (3). Tighten bolt (3) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).


    Illustration 10g01259747


    Illustration 11g06579483

  8. Use Tooling (G) to connect harness assembly (2).

    Note: The stop pin in Tooling (G) will prevent crushing the connector and reduce the chance for damage to wiring. Refer to "Electronic Unit Injector - Test" for more instructions.

  9. Install valve bridges (1).

    Note: Make sure that the slotted ends of the valve bridges are positioned toward the rocker arm shaft.

  10. Remove the air from the fuel system. Refer to Testing and Adjusting, "Fuel System - Prime".

End By:

  1. Install the rocker arms and the rocker arm shaft.

Information System:

C15 and C18 On-Highway Engines Exhaust Cooler (NRS) - Remove and Install
C15 and C18 On-Highway Engines Fuel Manifold (ARD) - Remove and Install
C15 and C18 On-Highway Engines Fuel Pressure Regulator - Remove and Install
C15 and C18 On-Highway Engines Fuel Transfer Pump - Remove and Install
C15 and C18 On-Highway Engines Fuel Filter Base - Remove and Install - Secondary
3500 Petroleum Engines and Petroleum Generator Sets Gauges and Indicators
C15 and C18 On-Highway Engines Fuel Priming Pump - Remove and Install
12M Series 3, 140M Series 3, 160M Series 3, 140, 150 and and 160 Motor Graders Location of Components (Steering System)
Three60 Precision Control System Programmable Parameters
14L Motor Grader Temperature Sensor (DPF Inlet, Flame Detect) - Remove and Install
C4.4 and C7.1 Engines Sensor Calibration Required - Test
2013/11/13 A New Front Cover Used On Certain C11 and C13 Industrial Engines {1151, 1162, 1206}
C15 and C18 On-Highway Engines Electronic Unit Injector Sleeve - Remove and Install
C15 and C18 On-Highway Engines Turbocharger - Remove and Install
C15 and C18 On-Highway Engines Air Control Valve - Remove and Install
C15 and C18 On-Highway Engines Exhaust Gas Valve (NRS) - Assemble
C15 and C18 On-Highway Engines Solenoid Valve (ARD Main Fuel) - Remove and Install
C15 and C18 On-Highway Engines Exhaust Manifold - Remove and Install
14L Motor Grader Pressure Sensor (ARD Main Fuel) - Remove and Install
14L Motor Grader Pressure Sensor (ARD Pilot Fuel) - Remove and Install
C9.3 Tier 4 Final Engines Valve Mechanism Cover
C13, C15, and C18 Tier 4 Final Engines Turbocharger
C13, C15, and C18 Tier 4 Final Engines Turbocharger
C13, C15, and C18 Tier 4 Final Engines Turbocharger