HANDHOLD GP 4519116 - Caterpillar

Start By:
Remove the rocker arms and the rocker arm shaft.
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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
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Remove valve bridges (1). Note the location and orientation of the valve bridges for installation purposes.
Disconnect harness assembly (2).
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If the injector hold down bolt is loose during the removal procedure, inspect the injector bore for wear and debris. Replace the clamp and spacer.
Remove bolt (3) and spacer (4) from clamp (5).
Place an identification mark on electronic unit injector (6) for installation purposes. Each electronic unit injector must be reinstalled in the original location in the cylinder head.
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Use Tooling (A) in bolt hole in order to pry clamp (5) and electronic unit injector (6) free from the cylinder head. Note: Improper use of Tooling (A) can cause damage to the spring or the unit injector.
Remove electronic unit injector (6) from the cylinder head.
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Remove O-ring seals (7) from electronic unit injector (6). Installation Procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Use Tooling (C) in order to remove the fuel and oil from the cylinder. Evacuate as much fuel and oil as possible from the cylinder before installing the electronic unit injector. Several evacuations may be necessary.
Use Tooling (D) in order to clean the carbon deposit from the inside of the electronic unit injector sleeve.
Use Tooling (E) in order to clean the carbon from the seat area that is inside of the electronic unit injector sleeve.
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Install O-ring seals (7) on electronic unit injector (6). Lubricate the top two O-ring seals with a 50/50 mixture of clean engine oil and Tooling (B).
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When an electronic unit injector is replaced, the new electronic injector code must be programmed into the engine's personality module software by using the calibration menu on the Electronic Service Tool. If the new electronic injector code is not entered, the characteristics of the previous electronic unit injector is assumed.If it is not possible to immediately reprogram the electronic injector code into the personality module software, the engine will not be severely harmed. The new electronic injector code should be reprogrammed as quickly as possible in order to optimize engine performance.
Install electronic unit injector (6) and clamp (5) into the original location in the cylinder head.
Install spacer (4) and bolt (3). Tighten bolt (3) to a torque of 55 10 N m (41 7 lb ft).
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Connect harness assembly (2).
Install valve bridges (1). Note: Make sure that the slotted end of the valve bridges are positioned toward the rocker arm shaft.
Remove the air from the