| NOTICE |
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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. |
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Personal injury or death may result from failure to adhere to the following procedures. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system. Turn the disconnect switch OFF or disconnect the battery when changing fuel filters. |
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 339-9352 | Cap Kit | - |
| 339-9353 | Cap Kit | - | |
| 339-9354 | Cap Kit | - | |
| 276-7018 | Cap Kit | - | |
- Relieve the fuel system pressure. Refer to Operation and Maintenance Manual, "System Pressure Release - Fuel System".
- Drain the Fuel System. Refer to Operation and Maintenance Manual, "Fuel System Primary Filter - Replace" for the correct draining and filling procedure.
- Use Tooling (A) to cap and plug all fuel system components. Capping and plugging all fuel system lines and components will prevent contamination of the fuel system.
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Illustration 1 g06164095 - Remove clip (1), and bolt (4).
- Disconnect wiring harness (2), and wiring harness (3). Position the wiring harnesses out of the way.
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Illustration 2 g06164099 - Disconnect wiring harness (5), wiring harness (7), sensor (8), and sensor (11). Position the wiring harnesses out of the way.
Note: If the high pressure fuel pump is being replace sensor (8), and sensor (9) must also be replaced.
- Remove bolts (6), bolts (10), and wiring harness (9).
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Illustration 3 g06164105 - Remove bolts (12), and control module (13).
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Illustration 4 g06245214 - Disconnect line (14), line (15), line (16), line (17), line (18), and line (19). Position the lines out of the way.
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Illustration 5 g06245224 - Remove clamp assembly (20). Remove tube assembly (21) and place in a clean, new resealable bag.
Note: Cap both ends of the tube assembly and plug all fuel ports.
- Remove hose (22).
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Illustration 6 g06245232 - Attach a suitable lifting device to fuel pump (23). The weight of fuel pump (23) is approximately
143 kg (315 lb) - Remove bolts (24), bolts (25), and fuel pump (23).
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Illustration 7 g06245247 - Loosen bolts (26) for possibly adjustments that may be required during reassembly.
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Illustration 8 g06245255 - Remove bolts (27), and cover (28).
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Illustration 9 g06245260 - Remove bolts (30), seal ring (31), and adapter plate (29).
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Illustration 10 g06245265 - Attach a suitable lifting device to adapter assembly (33). The weight of adapter assembly is approximately
39 kg (86 lb) . - Remove bolts (32), and adapter assembly (33).
- Ensure that all openings on the fuel injection pump, fuel lines, and fuel tubes have been capped or plugged using Tooling (A).
- Install fuel pump (23) in the reverse order of removal.
- Tighten end of tube assembly (21) to a final torque of
100 N·m (74 lb ft) . - Secure tube assembly (21) with clamp assembly (20). Tighten bolt to a torque of
55 N·m (41 lb ft) .
- Tighten end of tube assembly (21) to a final torque of
Note: Following repairs to the high-pressure fuel system, accumulator plugs on opened cylinders should be removed. A successful completion of the "Fuel Systems Function Test (FSFT)" using CATET must be performed. Upon completion of the FSFT, accumulator plugs are to be reinstalled.