C9.3 Engines for Caterpillar Built Machines Caterpillar

Disassembly Procedure

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NOTICE
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.

1. Drain diesel exhaust fluid into a suitable container for storage or disposal.
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   Illustration 1	g03365452

   Note: Refer to Special Instruction, REHS8231, "Removal Procedures for Diesel Exhaust Fluid (DEF) Connectors" for the correct removal procedure of hose assemblies (4).

2. Remove clips (1) and (5). Disconnect harness assemblies (2). Remove hose assemblies (4) and hoses (3).
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   Illustration 2	g03365463

3. Remove cable straps (6) and disconnect harness assembly (7).
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   Illustration 3	g03365465

4. Remove bolts (8), plate (9), manifold (10), and the gasket (not shown).
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   Illustration 4	g03365468

5. Remove bolts (11).
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   Illustration 5	g03365475

6. Remove bolt (12).
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   Illustration 6	g03365477

7. Remove bolts (13) and pump assembly (14).
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   Illustration 7	g03365493

8. Remove bolts (15) and bracket (16) from the tank .
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   Illustration 8	g03365514

9. Remove bolt (18) and cap (17). Remove bolts (19) and manifold (20).
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   Illustration 9	g03365521

10. Remove O-ring seals (23) from cap (21). Remove plug (24) and plug (25) from manifold (21).
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    Illustration 10	g03365528

11. Disconnect harness assembly (26) and remove solenoid assembly (27).
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    Illustration 11	g03365540

12. Remove relays (28).
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    Illustration 12	g03365547

13. Remove bolts (29). Remove control module (30).
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    Illustration 13	g03365554

14. Disconnect harness assembly (33). Remove cable straps (32). Remove electronic control (31).
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    Illustration 14	g03383608

15. Remove cover (34).
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    Illustration 15	g03383609

16. Remove expansion device (35).
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    Illustration 16	g03383610

17. Remove filter (36).
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    Illustration 17	g03366015

18. Remove cable straps (38), bolts (39), and bracket (37).
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    Illustration 18	g03366035

19. Disconnect harness assembly (40).
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    Illustration 19	g03366046

20. Remove bolts (41). Separate support assembly (42) from pump (43).
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    Illustration 20	g03366053

21. Remove cable straps (45) and harness assembly (44).
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    Illustration 21	g06003622

    Note: Place identification marks on DEF pump coolant connectors (46) and DEF pump connectors (47) for installation purposes. DEF pump coolant connectors (46) and DEF pump connectors (47) are not interchangeable.

22. Remove DEF pump coolant connectors (46) and DEF pump connectors (47) . Remove the O-ring seals.
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    Illustration 22	g06040542

23. Remove bracket (48). Remove hose assembly (49).
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    Illustration 23	g06040545

24. Remove nuts (53). Remove straps (52). Remove tank (50) from support assembly (51).