SEAL 2G8777 - Caterpillar

This procedure assists in identifying the cause for an injector misfiring. Perform this procedure only after performing a Fuel System Verification Test.
Check for air in the fuel, if this procedure has not already been performed. Refer to Testing and Adjusting, "Air in Fuel - Test".
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Do not open the high pressure fuel system without allowing the fuel system to purge. After the engine has shut down, allow the fuel system to purge for ten minutes. This operating fuel system contains high pressure. Exposure to high pressure fuel can result in personal injury.
Remove the valve cover and look for broken parts. Repair any broken parts or replace any broken parts that are found. Inspect all wiring for the solenoids. Look for loose connections. Also look for frayed wires or broken wires. Ensure that the connector for the unit injector solenoid is properly connected. Perform a pull test on each of the wires.
Look for signs of fuel leakage. Investigate the source of the leaking fuel. Remedy the cause of the fuel leak.
Check the valve lash setting for the cylinder of the suspect injector. Refer to Testing and Adjusting, "Engine Valve Lash - Inspect/Adjust".
Remove the suspect injector and check the injector for signs of exposure to coolant. Exposure to coolant will cause rust to form on the injector. If the injector shows signs of exposure to coolant, remove the injector sleeve and inspect the injector sleeve. Replace the injector sleeve if the injector sleeve is damaged. Check the injector for an excessive brown discoloration that extends beyond the injector tip. If excessive discoloration is found, check the quality of the fuel. Refer to Testing and Adjusting, "Fuel Quality - Test". Replace the seals on the injector and reinstall the injector. Inspect the injector for deposits of soot that are above the surface of the seat of the injector. Deposits of soot indicate combustion gas leakage. The source of the leak should be found, and the source of the leak should be remedied. The injector will not need to be replaced if combustion gas leakage was the problem. Note: The high-pressure fuel line must be replaced after removing the injector. The high-pressure fuel lines must only be used one time.
If the problem is not resolved, replace the suspect injector with a new injector. In order to verify that the new injector is working properly, perform a Fuel System Verification Test. Use the Caterpillar Electronic Technician (ET).