C6.6 Engines for Caterpillar Built Machines Valve Mechanism Cover Base - Remove and Install - Composite Valve Mechanism Cover Base Caterpillar

Removal Procedure

Start By:

1. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.

2. Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure.

Illustration 1	g01355167
Typical example

1. Make a temporary identification mark on connections (1).

2. Use a deep socket to remove connections (1) from electronic unit injectors (2).

3. Disconnect plugs (7) from harness assemblies (4).

4. If necessary, follow Step 4.a through Step 4.e in order to remove harness assemblies (4) from valve mechanism cover base (6).

   1. Cut cable strap (3).

   2. Use Tooling (A) to remove circlip (5).

   3. From the outside of valve mechanism cover base (6), push harness assembly (4) inward. Withdraw the harness assembly from valve mechanism cover base (6).

   4. Remove O-ring seal (8) from harness assembly (4).

   5. Repeat Step 4.a through Step 4.d in order to remove the remaining harness assembly.
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   Illustration 2	g01354234
   Typical example

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   Illustration 3	g01354235
   Tightening sequence for the valve mechanism cover base

5. Gradually loosen the captive bolts that secure the valve mechanism cover base in reverse numerical order. Refer to Illustration 3. Gradually loosen the captive bolts will help prevent distortion of the valve mechanism cover base.

   Note: The captive bolts cannot be removed from the valve mechanism cover base.

6. Remove valve mechanism cover base (6) from the cylinder head.

7. Remove seal (9) from valve mechanism cover base (6).

Installation Procedure

1. Clean the valve mechanism cover base. Ensure that the mating surfaces are free from damage.
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   Illustration 4	g01354234
   Typical example

2. Install seal (9) to valve mechanism cover base (6). Ensure that the seal is seated correctly in the groove in the valve mechanism cover base.
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   Illustration 5	g01354235
   Tightening sequence for the valve mechanism cover base

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   Illustration 6	g01419953

3. Position valve mechanism cover base (6) onto the cylinder head. Install Tooling (D) in Positions (X) in order to align the valve mechanism cover base.

4. Gradually tighten the captive bolts that secure the valve mechanism cover base to a torque of 9 N·m (79 lb in) in the sequence that is shown in Illustration 5.

5. Remove the Tooling (D) from Positions (X).
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   Illustration 7	g01355167
   Typical example

6. If necessary, install the harness assemblies for the electronic unit injectors. Follow Step 6.a through Step 6.e in order to install the harness assemblies to the electronic unit injectors.

   1. Ensure that harness assembly (4) and the bore in valve mechanism cover base (6) are clean and free from damage. Replace any damaged components.

   2. Use Tooling (B) to lubricate a new O-ring seal (8). Install O-ring seal (8) onto harness assembly (4).

   3. From the inside of valve mechanism cover base (6), push harness assembly (4) into the valve mechanism cover base.

   4. Use Tooling (A) to install circlip (5).

   5. Repeat Step 6.a through Step 8 for the remaining harness assembly.

7. Use a deep socket to connect harness (4) to electronic unit injectors (2). Use Tooling (C) to tighten connectors (1) to a torque of 2.4 N·m (21 lb in).

8. If necessary, install new cable straps (3) to harness assemblies (4).

   Note: Ensure that cable straps are to Original Equipment manufacture (OEM) specification.

9. Connect plugs (7) to harness assemblies (4).

End By:

1. Install new fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.

2. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.