Cleaning Procedure for Removing Debris

from the Oil Rail and Injector Bores on C7 &

C9 HEUI Engines
For use after a HEUI pump replacement

315B Injector

HEUI Pump C7 Cylinder Head C9 Cylinder Head

Background Information

 When to use this procedure:

– This procedure should be considered a supplement to Media #REHS3819-02 “Procedure for
Troubleshooting and Cleaning the Oil Rail System for the Hydraulic Electronic Unit Injector (HEUI)”
– When the flowchart on page 5 of REHS3819-02 leads to “Flush rail, Replace all injectors & HEUI pump”
this cleaning procedure should be substituted for the procedure outlined on pages 6-8 of REHS3819-02.
 Why this procedure is necessary:
– Because HEUI injectors are precision machinery they are sensitive to debris. If the cylinder head’s oil rail,
injector bores and connecting passages are not cleaned completely subsequent injector failures are likely
to occur. Moreover, when later injector failures occur the diagnostic procedure will find the old debris still in
the rail and the replacement HEUI pump will be mistakenly condemned and needlessly replaced.
 Why REHS3819-02 is being updated:
– Field experience has shown the cleaning method outlined in REHS3819-02 is inadequate at preventing
future injector failures.

Special thanks to Dustin Down at Altorfer Inc. in East Peoria, IL for sharing his procedure and for his patience.

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Cleaning Procedure – Required Supplies (See pictures on following Pages)

 Purchased Supplies
– Air powered, siphon fed solvent gun (Matco tools #CL16 or equivalent)
– Shop Vacuum
– Tapered Cap/ Plug (Cat #9U-7080)
– Brake Cleaner (Cat #222-3117 or equivalent)
– Mineral Spirits
– Person Protect Equipment (Safety glasses/ face shield, apron/ shop clothes) as needed to protect technician
– Drop light
– Shop air

 Shop Fabricated Supplies

– Approximately 20” long air line for use on end of solvent gun.
• Allows squirting deeper in oil rail
– Assembly of decreasing diameter vacuum, air or fuel line for use on end of shop vacuum
• Allows debris-laden fluid to be sucked out of injector bores
– Several spray can straws glued/ siliconed together to make a long squirting straw.
• Allows technician to spray into oil and fuel passages in injector bores while holding can upright

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Cleaning Procedure – Required Supplies

Solvent gun

Cap/ Plug 9U-7080

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Cleaning Procedure – Required Supplies

Solvent gun with Shop vacuum with

air hose on end decreasing diameter hoses

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Cleaning Procedure – Required Supplies

Shop-fabricated extra long squirting straw

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Cleaning Process – C7

 Passages connecting injector bores to

the rail slope down towards injector
bores.
 Presence of rail drain holes.
 General method:
– Blast oil rail with solvent gun
– Wash debris down to caps inserted in
injector bores
– Periodically suck dirty solvent out of Rail Drain Holes
caps in bottom of injector bores
– Repeat until no longer get debris in
caps
– Use brake cleaner and special straw to
spray out fuel passages from injector
bore to injector bore and oil passages
from injector bores to rail.
– Blow out rail through rear plug hole
(suck out with shop vac if rear plug is
inaccessible)
– INSPECT RAIL for debris with mirror
and light
– Repeat cleaning as necessary until no
more debris in rail Rail Drain Hole
Plugs

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Cleaning Process – C7

1) Using Media #REHS3819-02 “Procedure for Troubleshooting and Cleaning the Oil Rail System for the
Hydraulic Electronic Unit Injector (HEUI)”, determine that the injectors and pump must be replaced
and the oil rail cleaned of debris.
2) Remove fuel injectors. Refer to Disassembly and Assembly for specific machine. Note: Contain any
oil and cleaner that will flow from the cylinder and the lines during the following process. Properly
dispose of the oil and contaminated cleaner when work is complete.
3) Remove the plugs from the front and rear of the cylinder head’s main oil gallery
4) Remove the pressure sensor from the cylinder head. Protect the sensor.
5) Install six plugs (9U-7080 Tapered Cap/ Plug) into the lower injector bores. These will prevent oil,
cleaners and debris from entering the cylinders.
6) Clean out the two rail drain holes by removing their plugs and using the brake cleaner and long
squirting straw to flush these passages to the oil rail.
7) Using the solvent gun with and without the air hose extension blast mineral spirits into the rail,
washing debris down to the injector bores. Using a drop light shining into the injector bores from
above will allow monitoring of how much fluid is collecting in the tapered plugs.
8) When the plugs in the injector bores become full use the shop vacuum with decreasing diameter
tubing attached to suck out each injector bore.
9) Continue to repeat steps 7 & 8, squirting the solvent gun into the rail through every hole possible,
including the front and rear main gallery plug holes, the sensor hole, and the pump inlet hole. Using
the air hose extension on the solvent gun will allow the solvent to be directed more towards one
injector hole than the others. Monitor accumulation of dirty solvent in the cups while spraying solvent.

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Cleaning Process – C7

10)Clean rail until the fluid collecting in the tapered plugs has no more metallic debris. Note: Once the
oil is washed from the rail the runoff fluid collecting in the plugs will be clear but still contain debris.
Inspect with a drop light to ensure the absence of any shiny particles.
11)Once the rail is clean use the brake cleaner and long spraying straw in the injector bores to backflush
the passages from the injector bores to the rail.
12)Using the brake cleaner and long spraying straw in the injector bores flush out the fuel passages
between the injector bores.
13)Using the shop vacuum suck out the brake cleaner and debris from the injector bores.
14)Using the solvent gun blow out rail from front to back. Finish up with spraying just air. If rear plug
cannot be removed solvent will have to be sprayed in and then sucked out with the shop vacuum.
15)Using a drop light and small mirror inspect entire rail for debris. If any is found repeat cleaning
procedure until rail is completely clean of debris. Note: Extra time and care now will prevent a repeat
failure, an unhappy customer and having to do this procedure all over again to the same vehicle.
16)Double check fluid in caps has no debris, suck out fluid, remove caps, suck out cylinders.
17)Clean and reassemble the oil filter bypass valve.
18)Refer to Truck Engine News, SEBD6764, “A New Spring for the Oil Filter Bypass Valve and for the
Oil Cooler Bypass Valve is Now in Production”, Service Magazine, SEPD0718, “A New Spring for the
Oil Filter Bypass Valve and for the Oil Cooler Bypass Valve is Now in Production”, and Engine News,
SEBD9329, “A New Spring for the Oil Filter Bypass Valve and for the Oil Cooler Bypass Valve is Now
in Production” for the correct selection of the springs for the bypass relief valve and the oil cooler.
19)Reassemble engine, using replacement HEUI Pump and Injectors.
20)Replace the engine oil and the oil filter. Refer to Operation and Maintenance Manual for you specific
machine to determine refill capacity.

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Cleaning Process – C7

Cap/ Plug 9U-7080 Spraying Mineral

Installed in Injector Spirits into rail via
Bore front plug hole

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Cleaning Process – C7

Dirty oil collected Sucking out Once flushing

in cup injector bore using solvent runs clear
shop vacuum inspect for shiny
particles in fluid

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Cleaning Process – C7

Custom bending long Holding can upright while

spraying straw spraying into passages

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Cleaning Process – C7

Back flushing rail to

injector passage and fuel
passages. Notice fluid in
cup contains no shiny
particles

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Cleaning Process – C9

 Passages connecting injector bores to

the rail slope down towards oil rail.
 No rail drain holes.
 General method:
– Use brake cleaner and special straw to
spray out fuel passages from injector
bore to injector bore and oil passages
from injector bores to rail.
– Periodically suck dirty solvent out of
caps in bottom of injector bores as
needed
– Blast oil rail with solvent gun, flush
debris out rear main gallery plug hole
(suck out with shop vac if rear plug is
inaccessible)
– INSPECT RAIL for debris with mirror
and light
– Repeat cleaning as necessary until no
more debris in rail

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Cleaning Process – C9

1) Using Media #REHS3819-02 “Procedure for Troubleshooting and Cleaning the Oil Rail System for the
Hydraulic Electronic Unit Injector (HEUI)”, determine that the injectors and pump must be replaced
and the oil rail cleaned of debris.
2) Remove fuel injectors. Refer to Disassembly and Assembly for specific machine. Note: Contain any
oil and cleaner that will flow from the cylinder and the lines during the following process. Properly
dispose of the oil and contaminated cleaner when work is complete.
3) Remove the plugs from the front and rear of the cylinder head’s main oil gallery
4) Remove the pressure sensor from the cylinder head. Protect the sensor.
5) Install six plugs (9U-7080 Tapered Cap/ Plug) into the lower injector bores. These will prevent oil,
cleaners and debris from entering the cylinders.
6) Using the brake cleaner and long spraying straw in the injector bores flush the passages from the
injector bores to the rail.
7) Using the brake cleaner and long spraying straw in the injector bores flush out the fuel passages
between the injector bores.
8) Using the shop vacuum suck out the brake cleaner and debris from the injector bores as needed.
9) Using the solvent gun with and without the air hose extension blast mineral spirits into the rail,
washing debris out the rear plug hole. If rear plug cannot be removed solvent will have to be sprayed
in and then sucked out with the shop vacuum.

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Cleaning Process – C7

10)Continue to repeat steps 6-9, squirting the solvent gun into the rail through every hole possible,
including the front and rear main gallery plug holes, the sensor hole, and the pump inlet hole. Monitor
accumulation of dirty solvent in the cups while spraying solvent, suck out as required. Flush until the
mineral spirits and brake cleaner run clear with no shiny metallic particles. Note: The fluid will turn
clear as soon as the oil is washed out of the rail but flushing must continue until there are no more
shiny metallic particles.
11)Using a drop light and small mirror inspect entire rail for debris. If any is found repeat cleaning
procedure until rail is completely clean of debris. Note: Extra time and care now will prevent a repeat
failure, an unhappy customer and having to do this procedure all over again to the same vehicle.
12)Double check any fluid in caps has no debris, suck out fluid, remove caps, suck out cylinders.
13)Clean and reassemble the oil filter bypass valve.
14)Refer to Truck Engine News, SEBD6764, “A New Spring for the Oil Filter Bypass Valve and for the
Oil Cooler Bypass Valve is Now in Production”, Service Magazine, SEPD0718, “A New Spring for the
Oil Filter Bypass Valve and for the Oil Cooler Bypass Valve is Now in Production”, and Engine News,
SEBD9329, “A New Spring for the Oil Filter Bypass Valve and for the Oil Cooler Bypass Valve is Now
in Production” for the correct selection of the springs for the bypass relief valve and the oil cooler.
15)Reassemble engine, using replacement HEUI Pump and Injectors.
16)Replace the engine oil and the oil filter. Refer to Operation and Maintenance Manual for you specific
machine to determine refill capacity.

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