12

Disassembly and Assembly Section

g00511936
Illustration 22

9. Install plug (11) in the fuel manifold.

End By:

g00529729 a. Install the rocker shaft and the pushrods. Refer

Illustration 21
to Disassembly and Assembly, “Rocker Shaft
(12) Electronic injector code and Pushrod - Install”.

NOTICE
i01770685
When a fuel injector group is serviced, the new fuel
injector group’s electronic injector code must be pro- Electronic Unit Injector Sleeve
grammed into the engine’s personality module soft-
ware by using the calibration menu on the Electronic - Remove
Service Tool. If the new fuel injector group’s electronic
code is not entered, the previous fuel injector group’s SMCS Code: 1713-011
characteristics are assumed.
Removal Procedure
If it is not possible to immediately reprogram the elec-
tronic injector code of the injector into the personal- Table 5
ity module software, the engine will not be severely
Required Tools
harmed. The new electronic injector code should be
reprogrammed as quickly as possible in order to opti- Tool
Part
Part Description Qty
mize engine performance. Number
221-9778 Puller Stud 1
4. Position the unit injector (3) in the cylinder head 128-7889 Bridge Puller 1
assembly. Place the hold down clamp (10) at
the base of the unit injector. Push down on the A(1) 9U-6877 Thrust Bearing 1
return spring of the unit injector in order to seat 5P-8247 Hard Washer 1
the unit injector.
4K-0367 Nut 1
5. Install spacer assembly (9) and bolt (8) that (1) The tools that are listed in the chart are part of the 9U-6891
holds the unit injector in place. Injector Tool Group.

6. Pull the unit injector completely into the bore. Start By:
Tighten the bolt to a torque of 30 N·m (22 lb ft).
a. Remove the electronic unit injectors. Refer to
7. Install cap assembly (5). Tighten nuts (6) to a Disassembly and Assembly, “Electronic Unit
torque of 2.5 ± 0.25 N·m (22 ± 2 lb in). Injector - Remove”.

8. Install bridge assemblies (7) onto the valve

stems.
 13
Disassembly and Assembly Section

i01770693
NOTICE
Keep all parts clean from contaminants. Electronic Unit Injector Sleeve
- Install
Contaminants may cause rapid wear and shortened
component life. SMCS Code: 1713-012

Installation Procedure
Table 6
Required Tools
Part
Tool Part Description Qty
Number
A 4C-5552 Large Bore Brush 1
9U-7237 Brush Extension 1
B
9U-7244 End Brush 1
C 9U-7258 Driver Cap 1

g00512128
Illustration 23
NOTICE
Typical example
Keep all parts clean from contaminants.
1. Install the puller stud from Tooling (A) into the Contaminants may cause rapid wear and shortened
unit injector sleeve. component life.

g00512002
Illustration 24

2. Install the following parts from Tooling (A) over

the stud: bridge puller, thrust bearing, hard
washer, and nut. See Step 1.

3. Tighten the nut until the unit injector sleeve is

pulled free of the cylinder head assembly.

4. Remove Tooling (A) from the unit injector sleeve.

5. Repeat Steps 1 through 4 in order to remove the

remaining unit injector sleeves.
g00512115
Illustration 25

1. Use Tooling (A) to clean the unit injector bore.

2. Use Tooling (B) to clean the unit injector seat.

14
Disassembly and Assembly Section

Note: Check the fuel passage in the cylinder head

assembly. Remove any debris left from the use of
Tooling (A) and Tooling (B).

3. Apply 4C-9507 Retaining Compound to upper

land (1) and lower land (2) on the unit injector
sleeve.

g00911767
g00512116 Illustration 27
Illustration 26

1. Remove bolts (3).

4. Position the unit injector sleeve in the cylinder
head assembly. Use Tooling (C) and a hammer
2. Remove bolt (7) with the nut and the washer.
to seat the sleeve.
Remove saddle clamp (6).
5. Repeat Step 1 through Step 4 in order to install
3. Remove bolts (9) and the washers.
the remaining unit injector sleeves.
4. Disconnect fitting (8).
End By:
5. Remove oil supply tube (2) and the gasket.
a. Install the electronic unit injectors. Refer to
Disassembly and Assembly, “Electronic Unit
6. Remove bolts (4) and the washers.
Injector - Install”.
7. Remove oil drain tube (5). Remove the O-ring
i01781769 seal and the gasket from oil drain tube (5).

Turbocharger - Remove 8. Move hose clamp (11). Disconnect hose (10).

SMCS Code: 1052-011

Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.
 15
Disassembly and Assembly Section

g00911698 g00911698
Illustration 28 Illustration 29

9. Remove four nuts (13). Note: Refer to the Specifications Manual for the
tightening procedure of the clamps on specific
10. Remove turbocharger (1) and gasket (12) from turbochargers.
the exhaust manifold.
2. Place clean engine oil in the oil supply port of
the turbocharger prior to installation. The oil will
i01781774
provide lubrication during starting and protection
Turbocharger - Install during storage.

SMCS Code: 1052-012 3. Apply Tooling (A) to the turbocharger mounting

studs on the exhaust manifold.
Installation Procedure 4. Install turbocharger (1) and gasket (12) on the
exhaust manifold. Install nuts (13). Tighten the
Table 7
nuts to a torque of 70 N·m (52 lb ft).
Required Tools
Part
Tool Number Part Description Qty
(A) 5P-3931 Anti-Seize Compound 1

1. Inspect the condition of the gasket between the

turbocharger and the exhaust manifold and the
O-ring seals. Replace the O-ring seals and the
gaskets, if necessary.

g00911767
Illustration 30
16
Disassembly and Assembly Section

5. Place the gasket and the O-ring seal on oil drain

tube (5).

6. Install oil drain tube (5) with two bolts (4) and
the washers.

7. Install bolts (9) and the washers.

8. Install oil supply tube (2) and the gasket on

turbocharger (1). Install bolts (3) .

9. Connect fitting (8).

10. Install saddle clamp (6) and bolt (7).

11. Install hose assembly (10) onto the tube. Secure

the hose assembly with hose clamp (11).

i01781006

Modulating Valve - Remove g00912917

Illustration 31
and Install
1. Disconnect lines (1) from valve (3).
SMCS Code: 3139-010
2. Disconnect wiring harness assembly (5) from
Removal Procedure solenoid (4).

Note: Put identification marks on all hose 3. Remove bolts (2). Remove valve (3).
assemblies, on all wires, and on all tube assemblies
for installation purposes. Plug all hose assemblies 4. Remove solenoid (4) from valve (3).
and all tube assemblies. This helps to prevent fluid
loss, and this helps to keep contaminants from Installation Procedure
entering the system.
Note: Cleanliness is an important factor. Before
NOTICE assembly, all parts should be thoroughly cleaned
Care must be taken to ensure that fluids are contained in cleaning fluid. Allow the parts to air dry. Wiping
during performance of inspection, maintenance, test- cloths or rags should not be used to dry parts. Lint
ing, adjusting and repair of the product. Be prepared to may be deposited on the parts which may cause
collect the fluid with suitable containers before open- later trouble. Inspect all parts. If any parts are worn
ing any compartment or disassembling any compo- or damaged, use new parts for replacement. All
nent containing fluids. disassembly and all assembly procedures must be
performed on a clean work surface and in a clean
Refer to Special Publication, NENG2500, “Caterpillar hydraulic area. Keep cleaned parts covered and
Tools and Shop Products Guide” for tools and supplies protected at all times.
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.
 17
Disassembly and Assembly Section

g00512515
Illustration 33
Typical example

1. Remove locknuts (1) with the washers and

spacers.

Illustration 32 g00912917 2. Remove exhaust manifold (2) and the gaskets.

1. Install solenoid (4) onto valve (3). Tighten 3. Remove the studs that hold the exhaust manifold
solenoid (4) to a torque of 50 ± 5 N·m to the cylinder head assembly.
(37 ± 4 lb ft).
4. Remove studs (3) from the exhaust manifold, if
2. Install valve (3) in position. Secure valve (3) with necessary.
bolts (2).
Installation Procedure
3. Connect wiring harness assembly (5) to solenoid
(4). 1. Inspect the condition of the gasket. Replace the
gasket, if necessary.
4. Connect lines (1) onto valve (3).
2. Apply 5P-3931 Anti-Seize Compound to the
threads of the studs that hold the exhaust
i01465377
manifold to the cylinder head assembly.
Exhaust Manifold - Remove 3. Install the studs for the cylinder head assembly.
and Install Tighten the studs to a torque of 35 ± 5 N·m
(26 ± 4 lb ft).
SMCS Code: 1059-010

Removal Procedure
Start By:

a. Remove the turbocharger. Refer to Disassembly

and Assembly, “Turbocharger - Remove”.

g00512515
Illustration 34
Typical example

4. Position the gaskets with the tabs in the upward

position. Install exhaust manifold (2).
18
Disassembly and Assembly Section

5. Apply 5P-3931 Anti-Seize Compound to i01337547

locknuts (1). Install locknuts (1) with the washers
and spacers. Tighten the locknuts to a torque of Inlet Manifold - Install
55 ± 10 N·m (41 ± 7 lb ft).
SMCS Code: 1058-012
6. Apply 5P-3931 Anti-Seize Compound to the
threads of studs (3). Installation Procedure
7. Install studs (3) in exhaust manifold (2). Tighten NOTICE
the studs to a torque of 35 ± 5 N·m (26 ± 4 lb ft). Keep all parts clean from contaminants.
End By: Contaminants may cause rapid wear and shortened
component life.
a. Install the turbocharger. Refer to Disassembly
and Assembly, “Turbocharger - Install”.

i01337457

Inlet Manifold - Remove

SMCS Code: 1058-011

Removal Procedure
NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened g00707340

component life. Illustration 36
Typical example

1. Inspect the condition of the gaskets. Replace the

gaskets, if necessary.

2. Position air inlet manifold (6) and the three

gaskets on the cylinder head.

3. Install bolts (7) and the washers. Tighten bolts

(7) to a torque of 55 ± 10 N·m (40 ± 7 lb ft).

4. Install hose assembly (5).

5. Connect sensor connector (2).

g00707340 6. Install clip (4) and bolt (1). Tighten bolt (1) to a
Illustration 35
torque of 12 ± 3 N·m (9 ± 2 lb ft).
Typical example
7. Connect sensor connector (3).
1. Disconnect sensor connector (3).

2. Remove bolt (1) and clip (4).

3. Disconnect sensor connector (2).

4. Remove hose assembly (5).

5. Remove bolts (7) and the washers. Remove air

inlet manifold (6) and the three gaskets.
 19
Disassembly and Assembly Section

i01770734

Inlet and Exhaust Valve

Springs - Remove and Install
SMCS Code: 1108-010

Removal Procedure
Table 8
Required Tools
Part
Tool Part Description Qty
Number
g00526802
A 4C-6726 Valve Spring Compressor 1 Illustration 38

3. Install the remainder of Tooling (A).

Start By:

a. Remove the valve mechanism cover. Refer to

Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.

b. Remove the electronic unit injector. Refer to

Disassembly and Assembly, “Electronic Unit
Injector - Remove”.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
g00526803
Illustration 39

Note: The following procedure is for the removal

of the inlet valve springs and the exhaust valve
springs without removing the cylinder head. This
procedure can be performed on only one cylinder Personal injury can result from being struck by
at a time. This will prevent the inlet valves and the parts propelled by a released spring force.
exhaust valves from falling into the cylinder.
Make sure to wear all necessary protective equip-
1. Rotate the crankshaft in order to bring the piston ment.
to the top center position in the cylinder.
Follow the recommended procedure and use all
recommended tooling to release the spring force.

4. Tighten the nut on Tooling (A) in order to

compress the inlet valve springs and the exhaust
valve springs (2).

5. Remove retainer locks (3).

6. Remove Tooling (A).

g00526801
Illustration 37

2. Place the bottom portion of Tooling (A) on the

cylinder head. Install the hold down bolt (1) .