G5-55 CAT 3116 Injector Repair Kit

G5-55 CAT 3116 Injector Repair Kit

G5-55 is a complete repair kit for the Caterpillar 3116 unit injector. It gives the workshop the fixtures needed to hold and open the injector safely, together with the full range of nozzle needle valve shims used to set injection timing on this engine.

What Is Included

• Injector holding and disassembly fixture — knurled body with locking mechanism and adjusting collar, engraved CAT-3116

• Injector puller assembly — slide hammer with threaded rods for extracting the injector from the cylinder head

• Pivoting linkage plate — with brass locating pins, engraved CAT-3116

• Threaded adapter — connects the injector body to the fixture, engraved CAT-3116

• Split ring clamp block — square block with central bore for gripping the injector body

• Spring compression tool — heavy duty coil spring and threaded rod for compressing and releasing the injector spring

• Nozzle needle valve shim set A — 16.1 to 15.9 mm, ten steps of 0.02 mm, 50 pieces

• Nozzle needle valve shim set B — 15.9 to 15.7 mm, ten steps of 0.02 mm, 50 pieces

• Two compartmented storage boxes for the small renewal parts

Why Shim Adjustment Matters on the CAT 3116

The Caterpillar 3116 is a mechanical unit injector engine. Fuel quantity and injection timing on each injector are set by the nozzle needle valve shim, so the shim thickness directly decides when and how much fuel enters the cylinder. After an injector has been opened for repair, the original setting is lost and must be restored with the correct shim.

If the shim is wrong the engine will run rough, smoke, lose power, misfire or over-fuel a cylinder. Because this affects only one cylinder at a time, the fault is often hard to trace on the vehicle. G5-55 supplies both shim ranges in 0.02 mm steps, which covers the full adjustment window needed for a complete set of 3116 injectors.

How To Use G5-55

1. Remove the injector from the cylinder head using the puller assembly.

2. Fix the injector into the holding fixture and lock the body with the split ring clamp block.

3. Open the injector following the Caterpillar service procedure and remove the nozzle assembly.

4. Measure the existing needle valve shim, select the correct thickness from set A or set B and fit the new shim.

5. Re-assemble the injector and compress the spring with the spring compression tool.

6. Test the injector and refit it to the engine, then check the timing before returning the machine to service.

Compatible Engines

Caterpillar 3116 diesel engines in trucks, buses, marine and industrial applications. The same injector tooling is commonly shared with the related Caterpillar 3114 engine family.

Frequently Asked Questions

Do I need both shim sets? Yes. Set A covers 16.1 to 15.9 mm and set B covers 15.9 to 15.7 mm. Together they span the full adjustment range, so one kit lets you set up a complete engine.

Can injectors be repaired or must they be replaced? The 3116 unit injector is a serviceable assembly. Opened, cleaned and re-shimmed correctly it can be returned to service, which costs far less than fitting new injectors across the engine.

What else does a workshop need? A test bench or injector tester is recommended to verify the injector after repair, and a timing gauge set is needed for correct installation on the engine.

Is the shim thickness measured the same way on all cylinders? Refer to the Caterpillar specification for the specific engine serial number. The correct procedure is to measure each injector on its own and select the matching shim.

Related Products

Beacon also supplies the G5-38 CAT 3116 injector removal tool, the G2.9 3116 HEUI holding fixture and the full range of Caterpillar C7, C9, C13, C15 and C175 injector service tooling. If you maintain a fleet of Caterpillar machines we can assemble a combined package covering all of the CAT injector types you work on.

Contact

For pricing, packing details, shipping or technical questions, contact our sales team. We reply to technical enquiries within one working day and can supply high resolution photos, videos and injector setting tables on request.

Introduction

G5-55 CAT 3116 Injector Repair Kit is a workshop set for servicing Caterpillar 3116 unit injectors. It provides the holding and disassembly fixtures plus the complete range of nozzle needle valve shims needed to restore injection timing after an injector has been opened.

System Application

Caterpillar 3116 mechanical unit injector (EUI) diesel engine. Suitable for injector overhaul on trucks, buses, marine and industrial Caterpillar machines.

Remote Diagnostics

Beacon offers remote technical support for Caterpillar unit injector repair. Send us photos or video of the injector, the nozzle assembly and the shim measurement, and our engineers will advise on the correct shim grade and the setting procedure. Support is available during Chinese business hours.

12 Months Warranty

All Beacon tooling carries a 12 month warranty covering manufacturing defects.

After-Sales Service

Replacement shims, adapters and renewal parts are available as separate items, and additional nozzle needle valve shim sets in other ranges can be supplied on request. Contact us for a full Caterpillar injector service package.