2018/08/28 Electronic Unit Injector - Install (KENR6216)

SMCS - 1290 i07504778

Installation Procedure
Required Tools
Tool Part Number Part Description Qty
B 298-5564 T40 Torx Socket 1
1U-5718 Vacuum Pump 1
169-7372 Fluid Sampling Bottle 1
D
Tube
4C-4057 1
7.9 mm (0.31 inch) Outside Diameter
E 276-1216 Injector Pipe Nut Tool 1
F 247-5377 Torque Wrench 1

Table 1

NOTICE
Ensure that all adjustments and repairs that are carried
out to the fuel system are performed by authorized
personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to

Operation and Maintenance Manual, "General Hazard
Information and High Pressure Fuel Lines" for safety
information.

Refer to Systems Operation, Testing and Adjusting

Manual, "Cleanliness of Fuel System Components" for
detailed information on the standards of cleanliness
that must be observed during ALL work on the fuel
system.

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.

Dispose of all fluids according to local regulations and

mandates.

NOTICE
Use a deep socket to install the electrical connections from the
electronic unit injectors. Use of incorrect tooling will result in
damage to the electronic unit injectors.

https://sis2.cat.com/#/detail?tab=3&serialNumber=444&infoType=8&serviceMediaNumber=KENR6216&serviceIeSystemControlNumber=i02554031
 Illustration 1 g01772353
Typical calibration code

1. If a replacement electronic unit injector is installed, the correct trim file for the
injector must be programmed into the electronic control module. Refer to
Troubleshooting, "Injector Trim File" for more information. The code that is required
to obtain the trim file for the injector is at Position (X).
Note: Record Code (X) before the electronic unit injector is installed.

2. Use Tooling (D) to remove any fuel from the cylinder.

Note: Evacuate as much fuel as possible from the cylinder before installing the
electronic unit injector.

3. Ensure that the fuel inlet port of the electronic unit injector is capped. Ensure that
the electronic unit injector is clean.

Illustration 2 g01769574
Typical example

4. On installing an original electronic unit injector, install a new O-ring seal (16) and
sealing washer (15) to electronic unit injector (12).
Ensure that O-ring seal (16) and sealing washer (15) on a new electronic unit
injector are not damaged and in place.

Note: Do not lubricate the O-ring seal.

5. Ensure that the seat for the electronic unit injector in the cylinder head is clean and
free from damage. Ensure that the old sealing washer has been removed from the
cylinder head.

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 Illustration 3 g01769513
The rocker shaft is not shown for clarity.

6. Position clamp (14) between the rocker arm and the valve springs. Align electronic
unit injector (12) to the bore for the electronic unit injector in the cylinder head.
Install the clamp to the electronic unit injector. Ensure that the electronic unit
injector is pushed firmly against the seat in the cylinder head.

7. Install a new torx screw (13) to clamp (14). Tighten the torx screw finger tight.

8. Remove the cap from electronic unit injector (12). Install a new seal (9) to electronic
unit injector (12) and to the valve mechanism cover base. Ensure that the flange on
the seal is flush with the valve mechanism cover base.

9. Remove the plugs from the new fuel injection line. Loosely install the fuel injection
line. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install".
Note: Ensure that the ends of the fuel injection line are seated in the electronic unit
injector and the fuel manifold. Tighten the nuts finger tight.

10. Use Tooling (B) to tighten torx screw (13) to a torque of 27 N·m (239 lb in).
Note: Tooling (B) must be used to ensure no damage to the rocker arms.

11. Tighten the clamps and the fuel injection lines. Use Tooling (E) to tighten the fuel
injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install"
for more information.

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 Illustration 4 g01772534
Typical example

Illustration 5 g01774093
Typical example
The electronic unit injector is not shown for clarity.

NOTICE
Failure to ensure that ALL valve bridges are correctly seated
onto the valve stems will cause interference between the
pistons and the valves, resulting in damage to the engine.

12. Install valve bridges (5) to the cylinder head. If valve bridges (5) are equipped with
shrouds (6), ensure that the shrouds are located correctly.
Note: Ensure that used valve bridges are reinstalled in the original location and the
original orientation. Do not interchange the location or the orientation of used valve
bridges.

13. Ensure that the bottoms of the pushrods are seated in the cups of the valve lifters.
Locate the balls of adjusters (2) into the cups of pushrods (4). Adjust the valve lash.

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 Refer to Systems Operation, Testing and Adjusting, "Engine Valve Lash -
Inspect/Adjust".

14. Use a deep socket to install harness assembly (10) to electronic unit injector (12).
Use Tooling (F) to tighten connections (11) to a torque of 2.4 N·m (21 lb in).

Illustration 6 g01769493
Typical example

15. Tighten banjo bolt (8) on the fuel transfer pump for tube assembly (7). Tighten the
banjo bolt to a torque of 21 N·m (15 lb ft).

16. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve
Mechanism Cover - Remove and Install".

17. Turn the fuel supply to the ON position.

18. Turn the battery disconnect switch to the ON position.

19. Remove the air from the fuel system. Refer to Operation and Maintenance Manual,
"Fuel System - Prime" for more information.

Alternative Installation Procedure

Required Tools
Tool Part Number Part Description Qty
B 298-5564 T40 Torx Socket 1
1U-5718 Vacuum Pump 1
169-7372 Fluid Sampling Bottle 1
D
Tube
4C-4057 1
7.9 mm (0.31 inch) Outside Diameter
E 276-1216 Injector Pipe Nut Tool 1
F 247-5377 Torque Wrench 1

Table 2

Note: This is an optional procedure to install the electronic unit injectors. The method
should ONLY be used when all electronic unit injectors are installed and when the engine
is removed from the application.

NOTICE

https://sis2.cat.com/#/detail?tab=3&serialNumber=444&infoType=8&serviceMediaNumber=KENR6216&serviceIeSystemControlNumber=i02554031
 Ensure that all adjustments and repairs that are carried
out to the fuel system are performed by authorized
personnel that have the correct training.

Before beginning ANY work on the fuel system, refer to

Operation and Maintenance Manual, "General Hazard
Information and High Pressure Fuel Lines" for safety
information.

Refer to Systems Operation, Testing and Adjusting

Manual, "Cleanliness of Fuel System Components" for
detailed information on the standards of cleanliness
that must be observed during ALL work on the fuel
system.

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.

Dispose of all fluids according to local regulations and

mandates.

NOTICE
Use a deep socket in order to remove the electrical connections
from the electronic unit injectors. Use of incorrect tooling will
result in damage to the electronic unit injectors.

Illustration 7 g01772353
Typical calibration code

1. If a replacement electronic unit injector is installed, the correct trim file for the
injector must be programmed into the electronic control module. Refer to
Troubleshooting, "Injector Trim File" for more information. The code that is required
to obtain the trim file for the injector is at Position (X).
Note: Record Code (X) before the electronic unit injector is installed.
https://sis2.cat.com/#/detail?tab=3&serialNumber=444&infoType=8&serviceMediaNumber=KENR6216&serviceIeSystemControlNumber=i02554031
 2. Use Tooling (D) to remove any fuel from the cylinder.
Note: Evacuate as much fuel as possible from the cylinder before installing the
electronic unit injector.

3. Ensure that the fuel inlet port of the electronic unit injector is capped. Ensure that
the electronic unit injector is clean.

Illustration 8 g01769574
Typical example

4. On installing an original electronic unit injector, install a new O-ring seal (16) and
sealing washer (15) to electronic unit injector (12).
Ensure that O-ring seal (16) and sealing washer (15) on a new electronic unit
injector are not damaged and in place.

Note: Do not lubricate the O-ring seal.

5. Ensure that the seat for the electronic unit injector in the cylinder head is clean and
free from damage. Ensure that the old sealing washer has been removed from the
cylinder head.

Illustration 9 g01769513
Typical example

6. Install clamp (14) to electronic unit injector (12). Install the electronic unit injector
assembly into the original location in the cylinder head.
Note: Ensure that the electronic unit injector is pushed firmly against the seat in the
cylinder head. Install the electronic unit injector for number one cylinder first. Install
the electronic unit injectors in numerical order.

https://sis2.cat.com/#/detail?tab=3&serialNumber=444&infoType=8&serviceMediaNumber=KENR6216&serviceIeSystemControlNumber=i02554031
 7. Install a new torx screw (13) to clamp (14). Tighten the torx screw finger tight.

8. Remove the cap from electronic unit injector (12). Install a new seal (9) to electronic
unit injector (12) and to the valve mechanism cover base. Ensure that the flange on
the seal is flush with the valve mechanism cover base.

9. Remove the plugs from the new fuel injection line. Loosely install the fuel injection
line. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install".
Note: Ensure that the ends of the fuel injection line are seated in the electronic unit
injector and the fuel manifold. Tighten the nuts finger tight.

10. Use Tooling (B) to tighten torx screw (13) to a torque of 27 N·m (239 lb in).

11. Repeat Step 2 through Step 10 to install the remaining electronic unit injectors.
Tighten the clamps and the fuel injection lines. Use Tooling (E) to tighten the fuel
injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install"
for more information.

12. Use a deep socket to install harness assemblies (10) to electronic unit injectors
(12). Use Tooling (F) to tighten connections (11) to a torque of 2.4 N·m (21 lb in).

Illustration 10 g01774093
Typical example
The electronic unit injector is not shown for clarity.

NOTICE
Failure to ensure that ALL valve bridges are correctly seated
onto the valve stems will cause interference between the
pistons and the valves, resulting in damage to the engine.

13. Install valve bridges (5) to the cylinder head. If valve bridges (5) are equipped with
shrouds (6), ensure that the shrouds are located correctly.

14. Install the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker
Shaft and Pushrods - Install".

https://sis2.cat.com/#/detail?tab=3&serialNumber=444&infoType=8&serviceMediaNumber=KENR6216&serviceIeSystemControlNumber=i02554031
 Illustration 11 g01769493
Typical example

15. Tighten banjo bolt (8) on the fuel transfer pump for tube assembly (7). Tighten the
banjo bolt to a torque of 21 N·m (15 lb ft).

16. Turn the fuel supply to the ON position.

17. Turn the battery disconnect switch to the ON position.

18. Remove the air from the fuel system. Refer to Operation and Maintenance Manual,
"Fuel System - Prime" for more information.

4441-UP, 4631-UP, 5031-UP, 5441-UP, 5461-UP, 5F51-UP, A5D1-UP, B3D1-UP, B5E1-

UP, B5P1-UP, C341-UP, C4E1-UP, C5R1-UP, C5W1-UP, C5X1-UP, C5Y1-UP, CB51-UP,
CH31-UP, CH51-UP, D3W1-UP, D4B1-UP, D4D1-UP, D5W1-UP, DAN1-UP, DH61-UP,
DJL1-UP, DJM1-UP, EBL1-UP, ECK1-UP, ERP1-UP, FFF1-UP, GEK1-UP, GLD1-UP,
GLE1-UP, GTD1-UP, HJR1-UP, J3A1-UP, J3H1-UP, J5B1-UP, JLF1-UP, JLM1-UP, JTD1-
UP, JWK1-UP, K3D1-UP, K3J1-UP, K5E1-UP, KNP1-UP, LC41-UP, LC51-UP, LLL1-UP,
LYR1-UP, M451-UP, M4C1-UP, M4P1-UP, M4S1-UP, M5B1-UP, MFC1-UP, MMM1-UP,
MPC1-UP, MRW1-UP, MXB1-UP, P5F1-UP, PFM1-UP, PHC1-UP, PRA1-UP, RBA1-UP,
RBM1-UP, RLN1-UP, RRR1-UP, S4P1-UP, SAT1-UP, SCD1-UP, SWC1-UP, TWC1-UP,
W3H1-UP, W5M1-UP, WWW1-UP, YYY1-UP

PPI-0006E44A
2021/02/16
11:52:52+03:00
i02554031
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