DIESEL ENGINE COMPLETE 7S7983 - Caterpillar

Rework Procedure
Important Notes:
Common rail fuel technology requires a high degree of cleanliness. It is therefore imperative to adhere to all cleanliness requirements within this rework instruction, for example re-using dirty caps will have a detrimental effect on product durability.
Parts must be inspected prior to use to ensure capping is intact and parts are clean and undamaged.
All new components should remain bagged and capped until immediately before use.
Any fuel system component that is removed or exposed should be capped with new, clean caps to prevent dirt ingress, e.g. male connector when low-pressure pipe is removed.
Use anti contamination kit part No.278-4138.
Before attempting any work on the fuel system ensure that the engine is cleaned of any dirt that might contaminate the fuel system.
Clean up any spilt fuel before undertaking further work.
Check there is adequate clearance around all low-pressure pipes, and that any clipping is in place and correctly orientated.
NO attempt should be made to clean / flush filter elements for re-use.
DO NOT PRE-FILL THE FILTERS.
Fuel can be hot after running. Care must be taken to ensure hot fuel does not come in contact with exposed skin. Allow engine to cool before undertaking any work.
ELECTRONIC UNIT INJECTOR LEAK OFF TEST.
Ensure the fuel system components (and the surrounding area) are cleaned externally and free from debris prior to breaking into the fuel system ? see the section "Engine Clean" in the OMM.
Ensure that the engine is shut down. Locate the fuel leak off connector (1) on the cylinder head.
Image1.1.1
Remove the leak off pipe (2) from the connection on the cylinder head (1). Use a clean rubber hose, two hose clamps and a suitable bolt to make a sealed cap (3) for the end of the fuel leak off pipe (2). Insert a bolt (4) into the end of the rubber hose (6). Secure the bolt to the rubber hose with a hose clamp (5). Place the rubber hose assembly (3) onto the end of the fuel leak off pipe (2) and tighten the hose clamp (7).
Image1.2.1
Push a clean length of plastic hose (8) onto the leak off connector (1) on the cylinder head. Place the opposite end of the plastic hose (8) into a clean, graduated fuel container (9).
Image1.3.1
Disconnect the three wiring harness connectors (10) on the top cover in order to prevent the engine from starting.
Image1.4.1
Crank the engine with the starter motor for 30 seconds. Record the amount of fuel that has been collected in the container from the leak off connector on the cylinder head.
Repeat test a total of 3 times.
If the average fuel volume for the 3 leak off measurement readings is >50ml/30 seconds then the following fuel system components will also be required to be changed:
6 x Injectors
6 x High-pressure pipes (from fuel rail to injector)
6 x Injector clamp bolt (278-5170)
6 x Top cover sleeve (277-5067)
If the average fuel volume for the 3 leak off measurement readings are
The leak off pipe (1) should be re-connected to the cylinder head and the three wiring harness plugs (10) should be