ENGINE AR-CORE 3505502 - Caterpillar

Removal Procedure
Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     1U-7587     Pry Bar     1    
B     147-6456     Wedge Removal Tool     1    Start By:
Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
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.Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g00947495
Front oil gallery plug
Illustration 2 g00947501
Rear oil gallery plug
Remove plugs (1) and (2) . Drain the oil from the cylinder head oil gallery into a suitable container for storage or disposal.Note: Accessibility of the drain plug may vary according to the engine application.
Illustration 3 g00947503
Disconnect harness assembly (4) . Remove injection actuation pressure sensor (3) . Allow the engine oil to drain from the ports in the cylinder head before the unit injector is removed.
Illustration 4 g00948222
Illustration 5 g00947504
Latch clipNote: Minimal force is needed to lift the latch clip. Too much force will cause the latch clip to separate from the connector.Note: Use Tooling (B) or a small flat head screwdriver to unlock latch clip (7) on the harness assembly. Lift latch clip (7) by hand.
Disconnect harness assembly (7) from unit injector (5) .
Remove socket head bolts (6) from unit injector (5) .Note: When possible, remove the unit injector by hand by twisting the unit injector and pulling upward. Do not strike or hit the unit injector when you are removing the unit injector from the cylinder head.
If the unit injector can not be removed by hand, go to Step 6.
Illustration 6 g00948224
Note: Do not damage the unit injector during removal. Side loading may cause damage to the unit injector.
Place Tooling (A) on the flywheel side of unit injector (5) at Location (C) . Carefully remove unit injector (5) from the cylinder head.Note: Do not use a wire brush on the tip of the unit injector. Damage to the unit injector will occur.
Illustration 7 g00949104
Remove O-ring seals (10) , (11) , and (12) from unit injector (5) . Remove backup rings (8) , (9) , and (13) from unit injector (5) .
Repeat Steps 3 through 7 for the remainder of the unit injectors.