| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A(1) | 9U-6198 | Crankshaft Turning Tool | 1 |
| A(2) | 9U-7336 | Housing | 1 |
| 5P-7305 | Engine Turning Tool | 1 | |
| B | 367-8608 | Engine Timing Pin | 1 |
| C | 364-9107 | Fuel Pump Locking Pin | 1 |
| D | 370-8376 | Capping Kit | 1 |
| (1) | The Crankshaft Turning Tool is used on the front pulley. |
| (2) | This Tool is used in the aperture for the electric starting motor. |
Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
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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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Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
- Turn the fuel supply to the OFF position.
- Turn the battery disconnect switch to the OFF position.
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Illustration 1 g03343859 - Use Tooling (A) to rotate the crankshaft so that number one piston is at top dead center position . Refer to System Operation, Testing and Adjusting, "Fuel Injection Timing - Check". Use Tooling (B) to lock the crankshaft so that number one piston is at top dead center position.
- Remove plug (7). Use Tooling (C) to lock fuel injection pump (8).
- Clean fuel injection pump (8) and the area around the fuel injection pump. Ensure that the area is free from contamination before beginning disassembly.
- Loosen fuel line assembly (4) to drain fuel from the fuel system. Disconnect fuel line assembly (4). Use Tooling (D) to plug the tube assembly with a new plug. Cap the port in the fuel injection pump with a new cap.
- Disconnect fuel line assemblies (2) and (5) from fuel injection pump (8).
- Disconnect harness assembly (3).
Note: The harness assemblies should be positioned to avoid an obstruction to the fuel injection pump.
- Disconnect harness assembly (1).
- Remove line assembly (6)
- Use Tooling (D) to plug the open ports in the fuel injection pump and in the fuel manifold.
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Illustration 2 g03343876 - Remove nuts (9) and bolts (14).
- Remove Bolt (11) and spacer (10).
Note: The fuel injection pump should be supported by hand as the bolts are removed.
- Carefully remove fuel injection pump (8) from front housing (12).
- Remove gasket (13) (not shown).
- If necessary, remove the fuel injection pump gear and adaptor plate. Refer to Disassembly and Assembly, "Fuel Injection Pump Gear - Remove" for the correct procedure.
Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
- If necessary, use Tooling (A) to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Fuel Injection Timing - Check". Use Tooling (B) to lock the crankshaft so that number one piston is at top dead center position.
- If necessary, install Tooling (C) to lock the fuel injection pump in the correct position.
- Position a new gasket (13) (not shown) onto front housing (12).
- Position bolt (11) and spacer (10) onto fuel injection pump (10).
- Carefully install fuel injection pump (8) to front housing (12). Ensure that the bore in front housing (12) is not damaged as the fuel injection pump is installed.
Note: The fuel injection pump should be supported by hand as the nuts and bolts are installed.
- Tighten bolt (11) finger tight.
- Install nut (9) finger tight.
- Install new bolts (14) finger tight.
- Tighten bolts (14) and bolts (11) to a torque of
22 N·m (195 lb in) .Tighten nut (9) to a torque of
22 N·m (195 lb in) .Show/hide table
Illustration 4 g03343859 - Remove Tooling (C) from fuel injection pump (8).
- Remove Tooling (B) from the cylinder block. Install a new O-ring seal to the plug for the cylinder block. Install the plug to the cylinder block. Tighten the plug to a torque of
21 N·m (186 lb in) . - Install plug (7) to fuel injection pump (8). Tighten the plug to a torque of
14 N·m (124 lb in) . - Connect harness assembly (1).
- Connect harness assembly (3).
- Install fuel line assemblies (2) and (5).
- Install fuel line assembly (6).
- Replace the filters for primary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Primary (Water Separator) Element - Replace" for the correct procedure.
- Replace the filters for secondary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.
- Turn the fuel supply to the ON position.
- Turn the battery disconnect switch to the ON position.
- Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.
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| Illustration 3 | g03343876 |
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- After replacement of the fuel injection pump, the fuel injection pump requires a high-pressure fuel pump calibration procedure to be performed. Refer to Troubleshooting, "Fuel Rail Pressure Problem" for the correct procedure.