CAP 9D3089 - Caterpillar

Installation Procedure
Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     298-5564     T40 Torx Socket     1    
D     1U-5718     Vacuum Pump     1    
169-7372 Fluid Sampling Bottle     1    
4C-4057 Tube
7.9 mm (0.31 inch) Outside Diameter     1    
E     276-1216     Crows Foot Wrench     1    
F     247-5377     Torque Wrench     1    
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training.Before begining 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.
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.
Use a deep socket in order to install the electrical connections to the electronic unit injectors. Use of incorrect tooling will result in damage to the electronic unit injectors.
Illustration 1 g02353356
Injector code
If the original electronic unit injector (8) is installed , ensure that the electronic unit injector is installed into the original position.
If a replacement electronic unit injector is installed, the correct injector code must be programmed into the electronic control module. Refer to Troubleshooting, "Injector Code - Calibrate" for more information. The code that is required is located at Position (X) .Note: Record Code (X) before the electronic unit injector is installed.
Use Tooling (D) in order to remove any fuel from the cylinder.Note: Evacuate as much fuel as possible from the cylinder before installing the electronic unit injector.
Illustration 2 g02313273
If necessary, follow Step 4.a through Step 4.e in order to install a new harness assembly (6) to cylinder head (16) .
Install a new harness assembly (6) to cylinder head (16) .Note: Do not lubricate the O-ring seal.
Install a new bolt (14) to harness assembly (6) . Tighten the bolt to a torque of 5.5 N m (49 lb in).
Install new assemblies of cable strap (13) for harness assembly (6) to cylinder head (16) .Note: Ensure that the assemblies of the cable strap are correctly installed into the cylinder head.
Connect harness assembly (15) to harness assembly (6) .
If necessary, repeat Step 4.a through Step 4.e in order to install the remaining harness assemblies to the cylinder head.
Ensure that the fuel inlet port of the electronic unit injector is capped. Ensure that the electronic unit injector is clean.
Illustration 3 g01972153
New sealing washer (12) should only be installed if the original electronic unit injector (8) is to be reused.
On installing an original electronic unit injector, install a new