C6.6 Marine Generator Set Caterpillar

Removal Procedure

Start By:

1. Remove the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Remove" for the correct procedure.

2. Remove the heat exchanger. Refer to Disassembly and Assembly, "Exchanger - Remove" for the correct procedure.

3. Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove".

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Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

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Illustration 1	g01803655
The fuel manifold is shown with fuel injection lines in position.

1. If necessary, remove fuel pressure sensor (5). Refer to Disassembly and Assembly, "Fuel Pressure Sensor - Remove and Install".

2. If fuel pressure sensor (5) does not require removal, slide locking tab (4) into the unlocked position. Disconnect harness assembly (9) from fuel pressure sensor (5).

3. Disconnect tube assembly (6) from fuel pressure relief valve (7) on fuel manifold (3). Immediately cap the open port in fuel pressure relief valve (7) with a new cap. Immediately plug the open end of tube assembly (6) with a new plug.
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   Illustration 2	g01803653

4. If necessary, remove fuel pressure relief valve (7) from fuel manifold (3). Use a deep socket in order to remove the fuel pressure relief valve.

   Note: Fuel pressure relief valve (7) must only be removed at position (X). The fuel pressure relief valve is a two-piece assembly which should not be disassembled.

5. Remove bolts (2) from fuel manifold (3) and remove bracket (1).

6. Remove fuel manifold (3) and remove bracket (8).

Installation Procedure

1. Ensure that all ports on the fuel manifold are capped. Ensure that the fuel manifold is externally clean and free from damage.

   Note: Do not install a fuel manifold that has not been capped. All caps must be left in place until the fuel injection lines or the fuel pressure sensor are installed.

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   Illustration 3	g01803655
   The fuel manifold is shown with fuel injection lines in position.

2. Position fuel manifold (3) on mounting bracket (8).

3. Install bracket (1) to fuel manifold (3).

4. Install bolts (2) to fuel manifold (3) finger tight.

5. Install a new set of fuel injection lines and new seals. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for more information.

6. Tighten bolts (2) to a torque of 22 N·m (16 lb ft).
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   Illustration 4	g01803653

7. If necessary, install a new fuel pressure relief valve (5). Use a deep socket in order to install the fuel pressure relief valve. Tighten the fuel pressure relief valve to a torque of 120 N·m (89 lb ft).

   Note: Fuel pressure relief valve (5) must only be tightened at position (X). The fuel pressure relief valve is a two-piece assembly which should not be disassembled.

8. Remove the plug from tube assembly (6). Remove the cap from the fuel pressure relief valve on fuel manifold (3). Connect tube assembly (6) to the fuel pressure relief valve on fuel manifold (3). Tighten the connection to a torque of 30 N·m (22 lb ft).

9. If fuel pressure sensor (5) was not removed from fuel manifold (3), connect harness assembly (9) to fuel pressure sensor (5). slide locking tab (4) into the locked position.

   If fuel pressure sensor (5) was removed from fuel manifold (3), install fuel pressure sensor (5) and a new sealing washer. Refer to Disassembly and Assembly, "Fuel Pressure Sensor - Remove and Install" for more information.

10. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for more information.

End By:

1. Install the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Install" for the correct procedure.

2. Install the heat exchanger. Refer to Disassembly and Assembly, "Exchanger - Install" for the correct procedure.