25/11/23, 11:01 SIS 2.
Unit Injector - Install (RENR9218-14)
SMCS - 1290 i09728925
Installation Procedure
PSP
202 -0009
Table 1
15: 3/11/2 B659
Required Tools
Tool Part Number Part Description Qty
A 367-3070
0 1
Fuel Injector Installer As
RE : 5 1
D - Scotch Brite
N 3 6-0 1
© 2 R92 4:00
E 149-2955 Seal Protector 1
023 18
F 149-2956 Seal Installer 1
1U-5718 Vacuum Pump 1
169-7372 Bottle Assembly
Cat 1
G 4C-4057
Clear Plastic Tubing
erp 1
7.92 mm (0.312 inch) OD
illa
4C-4055
Clear Plastic Tubing
6.35 mm (0.250 inch) OD r In 1
H 9U-5470 Reamer c. 1
J 4C-6161 Tube Brush 1
K 9U-6862 Tapered Brush 1
L 4C-6774 Vacuum Gun Kit 1
M 4C-5027 Tap Wrench 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component
life.
1. Evacuate as much fuel and oil as possible from the cylinder head before installing the unit
injector. Several evacuations may be necessary. Use Tooling (G) to remove the fuel and oil
from the cylinder.
Note: Tooling (L) is available to clean loose material from the sleeve bore and the cylinder.
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2. Clean the carbon from the sleeve, the sleeve bore, and the end of the unit injector. Clean the
carbon from the seat area that is inside of the cylinder head. A fine grade of Tooling (D) is
preferred. Clean the carbon from the cylinder head and sleeves. If the sleeve of the unit injector
has been removed from the engine, use Tooling (H) to remove the carbon. If the sleeve of the
unit injector is installed in the engine, use Tooling (J) to remove the carbon.
The following procedure is the preferred method of cleaning the sleeve bore.
Place a 38 mm (1.5 inch) square piece of Scotch Brite material on the end of Tooling (K). Twist
Tooling (K) with Tooling (M) against the lower surface of the sleeve bore.
The surface should be cleaned until the surface is smooth and shiny. The entire sleeve bore
should be cleaned in order to remove any loose carbon particles.
Note: Tooling (L) is available to clean loose material from the sleeve bore and the cylinder.
NOTICE
The correct procedures and tooling specifications must always
be used. Failure to follow any of the procedures may result in
damage, malfunction, or possible engine failure.
NOTICE
The O-ring seals and the backup rings must be installed in the
correct orientation. Damaged seals will result in excessive oil
consumption or excessive leakage under the valve cover. Use
care to prevent nicks or damage to the seals.
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25/11/23, 11:01 SIS 2.0
Illustration 1 g01123753
3. Lubricate O-ring seal (6), O-ring seal (7), O-ring seal (8), and the sleeve bore of the unit injector
sparingly with clean engine oil.
4. Use Tooling (E) and Tooling (F) to install backup ring (4), backup ring (5), O-ring seal (6),
backup ring (9), and O-ring seal (8).
5. Install O-ring seal (7).
6. Lubricate the O-ring seals and the backup rings on the unit injector with clean engine oil before
installation.
Note: Proper installation of the unit injector is important. Damage to the upper high-pressure
seals can cause excessive oil leakage under the valve cover. The damage may cause the
engine not to start due to a low actuation pressure. Damage to the lower high-pressure seals
may allow high-pressure oil to leak into the fuel supply passage resulting in excessive oil
consumption.
Note: Do not hit or strike the unit injector during installation.
7. Record the serial number for the injector and the confirmation code for the injector. When a
new unit injector is installed, the E-Trim value must be programmed into the Engine Control
Module. For more information, refer to Troubleshooting, "Injector Code - Calibrate".
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25/11/23, 11:01 SIS 2.0
Illustration 2 g03028295
Illustration 3 g02608718
8. Use Tooling (A) to install unit injector (2) into the cylinder head.
9. Install socket head bolt (1b) on the exhaust side of the bracket. Tighten the exhaust side of
socket head bolt (1b) until the bolt is seated.
10. Install socket head bolt (1a) on the inlet side of the bracket. Tighten the inlet side of socket
head bolt (1a) to a torque of 12 ± 1 N·m (106 ± 9 lb in).
11. Connect harness assembly (3).
End By:
a. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Remove and Install".
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25/11/23, 11:01 SIS 2.0
PSP-0009B659
2023/11/25
[Link]-04:00
i01899385
© 2023 Caterpillar Inc.
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