C6.6 Marine Generator Set Caterpillar

Installation Procedure

Note: The following procedure should be adopted in order to install the fuel injection lines when the electronic unit injectors or the fuel manifold have not been removed. If the electronic unit injectors or the fuel manifold have been removed, refer to Disassembly and Assembly, "Electronic Unit Injector - Install" and Disassembly and Assembly, "Fuel Manifold - Install" for more information.

Show/hide table

Illustration 1	g01742480

Show/hide table

Illustration 2	g01742476

1. Loosely install tube clips (17) and allen head screws (18) to fuel injection line (11).

2. Place fuel injection line (11) in position.

3. Remove the caps from the port in fuel injection pump (12) and from the appropriate port in fuel manifold (9). Remove the caps from new fuel injection line (11).

4. Loosely connect the nuts at both ends of fuel injection line (11), to fuel manifold (9) and to fuel injection pump (12). Ensure that the ends of the fuel injection line are correctly seated in the fuel injection pump and in the fuel manifold.

5. Install bolts (16) finger tight for tube clips (17) that secure fuel injection line (11).

6. Use Tooling (A) to tighten the nuts on fuel injection line (11) to a torque of 30 N·m (22 lb ft).

7. Tighten bolts (16) to a torque of 22 N·m (16 lb ft). Tighten allen head screws (18) to a torque of 10 N·m (89 lb in). Ensure that fuel injection line does not contact any other engine component.
   Show/hide table

   Illustration 3	g01742453

8. Connect harness assembly (13) to position sensor (15). Slide locking tab (14) into the locked position. Connect harness assembly (13) to fuel injection pump (12).

9. For engines that are keel cooled and sea water cooled, Install the mounting bracket, the aftercooler and the heat exchanger. Refer to Disassembly and Assembly, "Aftercooler - Install" and ref to Disassembly and Assembly, "Heat Exchanger- Install" for the correct procedure.
   Show/hide table

   Illustration 4	g01742474

10. Install a new seal (10) to electronic unit injector (6). Ensure that the flange on the seal is flush with the valve mechanism cover base.

11. Remove the caps from the port of electronic unit injector (6) and from the appropriate port in fuel manifold (9).

12. Loosely connect the nuts at both ends of fuel injection line (7), to electronic unit injector (6) and to the appropriate port in fuel manifold (9). Ensure that the ends of the fuel injection line are correctly seated in the electronic unit injector and in the fuel manifold.

13. Use Tooling (A) to tighten the nuts on fuel injection line (7) to a torque of 30 N·m (22 lb ft).

14. Follow Step 10 through Step 13 in order to install the remaining fuel injection lines.

15. Install new plastic clamps (8) to the fuel injection lines. Ensure that the clamps are fully closed in order to retain the fuel injection lines.

    Note: Ensure that fuel injection lines do not contact any other engine component.

    Show/hide table

    Illustration 5	g01617993

16. If necessary, install grommets (5) to cover (1). Install washers (3) to bolts (2), and spacers (4). Install the cover and install bolts. Tighten bolts to a torque of 22 N·m (16 lb ft).

17. Connect breather hose from the valve mechanism cover and tighten hose clamp securely.

18. Turn the fuel supply to the ON position.

19. Turn the battery disconnect switch to the ON position.

20. Remove the air from the fuel system. Refer to Operations and Maintenance Manual, "Fuel System - Prime".