Procedure to Install High-Pressure Fuel Pump on Certain 793F Off-Highway Truck Engines {1255, 1256} Caterpillar

Off-Highway Truck/Tractor

793F (S/N: D3T142-160)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

This Special Instruction describes the procedure for installing the new high-pressure fuel pump on certain 793F off-highway truck engines.

Safety Section

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

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When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

Required Parts

Table 1 contains the part numbers required for this change.

Required Tools

Removal Procedure

Note: Retain all parts and hardware that are removed, unless noted.

Note: Ensure that all the fuel system components and openings are bagged or covered during disassembly.

1. Release the residual pressure in the high-pressure fuel rail.

   Reference: Refer to Operation and Maintenance Manual, SEBU9357, "High-Pressure Fuel System - Pressure Release".

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   Illustration 1	g06356130
   (A) 296-2679 Inlet Manifold (B) 341-4033 Inlet Manifold

2. Remove inlet manifold (A) and inlet manifold (B) using the reference given below.

   Reference: Refer to Disassembly and Assembly, M0080117, "Air Inlet Manifold –Remove and Install".

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   Illustration 2	g06351850
   (C) 540-4513 Engine Harness As

3. Disconnect engine harness assembly (C) from the high-pressure fuel pump system.
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   Illustration 3	g06352448
   (D) 325-7472 Pressure Sensor Gp (E) 320-3061 Pressure Sensor Gp

4. Disconnect pressure sensor group (D) from pressure sensor group (E).
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   Illustration 4	g06386504
   (F) 494-4922 Hose As (G) 500-2695 Check Valve Gp (H) 488-1849 Adapter As (J) 494-4921 Hose As

5. Remove and discard hose assembly (F) from check valve group (G) and adapter assembly (H).

6. Disconnect hose assembly (J) from adapter assembly (H).
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   Illustration 5	g06386531
   (K) 491-3757 Fuel Pump Gp (L) 443-5167 Hose As (M) 461-5814 Pump Adapter (N) 492-6182 Oil Supply Lines (P) 437-3327 Check Valve

7. Remove hose assembly (L) from fuel pump group (K) and check valve (P).

8. Disconnect oil supply line (N) from pump adapter (M).
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   Illustration 6	g06352022
   (Q) 509-5975 Hose As (R) 2T-2991 Connector (S) 6V-9853 Elbow

9. Remove hose assembly (Q) from connector (R) and elbow (S).
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   Illustration 7	g06351976
   (K) 491-3757 Fuel Pump Gp (T) 489-7591 Fuel Collector Lines Gp (U) 470-8630 Hose As

10. Disconnect fuel collector line (T) from fuel pump group (K).

11. Disconnect hose assembly (U) from fuel pump group (K).
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    Illustration 8	g06351987
    (K) 491-3757 Fuel Pump Gp (W) 363-3248 Sensor Harness As (X) 6V-5842 Bolt (Y) 6V-5839 Washer (Z) 250-7099 Mount (AA) 238-0112 Temperature Sensor Gp

12. Disconnect sensor harness assembly (W) from temperature sensor (AA).

    1. Remove bolt (X), washer (Y), and mount (Z) to remove sensor harness assembly (W).

    2. Remove temperature sensor (AA) from fuel pump group (K).
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    Illustration 9	g06351994
    (AB) 6V-3668 Bolt (AC) 5P-8245 Hard Washer (AD) 115-5579 Connecting Clip Assembly (AE) 8T-0293 Bolt (AF) 290-7493 Plate As

13. Remove bolt (AB), hard washer (AC), connecting clip assembly (AD), and bolt (AE).

    1. Remove and discard plate assembly (AF) from the fuel pump.
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    Illustration 10	g06352009
    (K) 491-3757 Fuel Pump Gp (AG) 437-0014 Junction Block (AH) 437-0032 Fuel Line (AJ) 6E-1435 Spacer (AK) 431-9373 Clamp As (AL) 8T-0644 Bolt (AM) 8T-7934 Hard Washer

14. Remove bolt (AL), hard washer (AM), clamp assembly (AK), and spacer (AJ).

    1. Remove and discard fuel line (AH) from junction box (AG) and fuel pump group (K).
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    Illustration 11	g06352539
    (T1) 439-3940 Bracket As (T2) 6V-3668 Bolt (T3) 5P-8245 Hard Washer (T4) 484-3313 Fuel Pump Kit (K) 491-3757 Fuel Pump Gp (AN) Lifting Point (AP) Lifting Point

15. Install fuel pump kit (T4) onto fuel pump group (K).

    1. Install 2 bracket assemblies (T1) onto fuel pump group (K) at lifting point (AN) and lifting point (AP) using 2 bolts (T2) and 2 hard washers (T3).

    2. Attach the bracket assemblies to a suitable lifting device.

       Note: The weight of the fuel pump is approximately 122 kg (269 lb).

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    Illustration 12	g06354077
    (AQ) 447-7163 Fuel Transfer Pump Gp (AR) 321-8648 Connector As

16. Connector assembly (AR) may be removed to provide clearance for removal of fuel transfer pump (AQ).
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    Illustration 13	g06354564
    (AQ) 447-7163 Fuel Transfer Pump Gp (AS) 522-6027 Bracket As (AT) 292-3198 Hard Washer (AU) 259-2627 Bolt (AV) 323-3731 Bolt (AW) 242-9985 Spacer (AX) Bracket

17. Remove 2 bolts (AV) and 2 spacers (AW) from fuel transfer pump group (AQ)

    1. Remove 2 bolts (AT) and 2 hard washers (AU) from bracket (AX).

    2. Remove bracket assembly (AS).
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    Illustration 14	g06351252
    (K) 558-5880 Fuel Pump Gp (AQ) 447-7163 Fuel Transfer Pump Gp (AY) 6V-7673 Bolt (AZ) 5P-8245 Hard Washer

18. Remove 2 bolts (AY) and 2 hard washers (AZ).

    1. Remove fuel transfer pump group (AQ) from fuel pump group (K).
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    Illustration 15	g06385993
    (K) 558-5880 Fuel Pump Gp (BA) Pump Adapter (BB) 202-6473 Bolt (BC) 5T-8224 Spacer

19. Remove 4 bolts (BB) and 4 spacers (BC) from fuel pump group (K).

    1. Remove fuel pump group (K) from pump adapter (BA).
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    Illustration 16	g06353220
    (BD) 508-8561 Sensor Harness As

20. Disconnect and discard sensor harness assembly (BD) shown in Illustration 16.
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    Illustration 17	g06385741
    (Y) 6V-5839 Washer (BD) 508-8561 Sensor Harness As (BE) 6V-4249 Bolt (BF) 8T-1893 Clip (BG) 8T-1894 Clip (BH) 1W-4955 Spacer (BJ) 353-7956 Grommet (BK) 9X-6772 Cable Strap (BL) 6V-4248 Bolt (BM) 8T-1889 Clip (BN) 8T-1890 Clip (BP) 132-7551 Spacer (BQ) 6V-0826 Grommet

21. Remove bolt (BE) with washer (Y), clip (BF), clip (BG), grommet (BJ), and spacer (BH).

    1. Remove cable strap (BK).

    2. Remove bolt (BL) with washer (Y), clip (BM), clip (BN), and spacer (BP).

    3. Remove grommet (BQ).
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       Illustration 18	g06385760
       (Y) 6V-5839 Washer (BD) 508-8561 Sensor Harness As (BM) 8T-1889 Clip (BN) 8T-1890 Clip (BP) 132-7551 Spacer (BR) 8T-4136 Bolt (BS) 177-4562 Grommet (BT) 6V-1820 Bolt

    4. Remove bolt (BR) with washer (Y), clip (BM), clip (BN), and spacer (BP).

    5. Remove grommet (BS).

    6. Remove bolt (BT) with washer (Y), spacer (BP), clip (BM), clip (BN), and grommet (BS).
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       Illustration 19	g06385744
       (Y) 6V-5839 Washer (BD) 508-8561 Sensor Harness As (BM) 8T-1889 Clip (BN) 8T-1890 Clip (BS) 177-4562 Grommet (BU) 6V-6317 Bolt

    7. Remove bolt (BU) with washer (Y), clip (BM), clip (BN), and grommet (BZ).
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    Illustration 20	g06353239
    (P) 437-3327 Check Valve (BV) 419-6028 Fuel Filter Gp (BW) 320-3060 Pressure Sensor Gp (BX) 6V-8076 Elbow

22. Remove check valve (P) from fuel filter group (BV).

23. Remove 2 pressure sensor groups (BW) from 2 elbows (BX).

24. Remove 2 elbows (BX).

Installation Procedure

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Illustration 21	g06350320
(1) 238-5082 O-Ring Seal (2) 6V-8637 Connector (BV) 419-6028 Fuel Filter Gp

1. Install 2 connectors (2) with 2 o-ring seals (1) into fuel filter group (BV).
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   Illustration 22	g06350317
   (2) 6V-8637 Connector (3) 228-7092 O-Ring Seal (4) 9X-2538 Elbow

2. Install 2 elbows (4) onto both connectors (2) with 2 o-ring seals (3).
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   Illustration 23	g06350313
   (4) 9X-2538 Elbow (5) 538-9500 Adapter (6) 228-7100 O-Ring Seal

3. Install adapter (5) with o-ring (6) into each elbow (4).
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   Illustration 24	g06361092
   (4) 9X-2538 Elbow (5) 538-9500 Adapter (7) 228-7100 O-Ring Seal (8) 325-7471 Pressure Sensor Gp

4. Install pressure sensor (8) with o-ring seal (7) into each adapter (5).
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   Illustration 25	g06350894
   (P) 437-3327 Check Valve (BV) 419-6028 Fuel Filter Gp (9) 238-5082 O-Ring Seal (10) 214-7568 O-Ring Seal (11) 228-7092 O-Ring Seal

5. Install check valve (P) into fuel filter group (BV) with o-ring seal (9), o-ring seal (10), and o-ring seal (11).
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   Illustration 26	g06350349
   (BY) Bracket (BZ) Plate (12) 477-0559 Bracket As (13) 4P-7581 Clip (14) 6V-5839 Washer (15) 6V-4248 Bolt (17) 127-9323 Bracket As (18) 091-0081 Spacer (19) 6V-3822 Bolt

6. Install bracket assembly (12) with bolt (15) and washer (14) to bracket (BY).

   1. Install bolt (15) with washer (14), and clip (13) into bracket assembly (12).

7. Install bracket assembly (17) with bolt (19), washer (19), and spacer (18) to plate (BZ).
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   Illustration 27	g06353780
   (20) 566-3362 Harness

8. Connect harness (20) to all the connections shown in Illustration 27.
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   Illustration 28	g06385787
   (Y) 6V-5839 Washer (BE) 6V-4249 Bolt (BF) 8T-1893 Clip (BG) 8T-1894 Clip (BH) 1W-4955 Spacer (BJ) 353-7956 Grommet (BL) 6V-4248 Bolt (BM) 8T-1889 Clip (BN) 8T-1890 Clip (BP) 132-7551 Spacer (BQ) 6V-0826 Grommet (CA) Plate As

9. Install grommet (BQ), clip (BM), and clip (BN) around harness (20).

   1. Install bolt (BL) with washer (Y) through clip (BM), clip (BN), and spacer (BP) to secure harness (20) to plate assembly (CA).

10. Install grommet (BJ), clip (BF), and clip (BG) around harness (20).

    1. Install bolt (BE) with washer (Y) through clip (BF) and clip (BG).

    2. Install spacer (BH) on the end of bolt (BE) and install the bolt onto the engine.
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    Illustration 29	g06385794
    (12) 477-0559 Bracket As (13) 4P-7581 Clip (17) 127-9323 Bracket As (20) 566-3362 Harness (21) 9X-6772 Cable Strap (22) 177-4562 Grommet (23) 6V-3822 Bolt (24) 6V-5839 Washer (25) 8T-1889 Clip (26) 8T-1890 Clip (27) 132-7551 Spacer (28) 6V-4248 Bolt

11. Install grommet (22), clip (25), and clip (26) around harness (20).

    1. Install bolt (23) with washer (24) through clip (25) and clip (26).

    2. Install spacer (27) on the end of the bolt and install the bolt onto bracket assembly (12).

    3. Secure harness (20) to clip (13) with cable strap (21).

12. Install bolt (28) with washer (24) and clip (13) onto bracket (17).

    1. Secure harness (20) to clip (13) with cable strap (21).
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    Illustration 30	g06350388
    (BA) Pump Adapter (29) 3P-1156 O-Ring Seal (30) 459-6534 Filter Screen As (31) 330-3517 O-Ring Seal

13. Install o-ring seal (29) and o-ring seal (31) into pump adapter (BA).

14. Install filter screen assembly (30) into pump adapter (BA).
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    Illustration 31	g06351362
    (CB) Protective Caps (32) 558-5880 Fuel Pump Gp (33) 6V-5553 O-Ring Seal

15. Remove protective caps (CB) from fuel pump group (32).

    1. Install o-ring seal (33) onto fuel pump group (32).
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    Illustration 32	g06354373
    (T1) 439-3940 Bracket As (T2) 6V-3668 Bolt (T3) 5P-8245 Hard Washer (CC) Lifting Point (CD) Lifting Point (32) 558-5880 Fuel Pump Gp

16. Install 2 bracket assemblies (T1) onto fuel pump group (32) at lifting point (CC) and lifting point (CD) using 2 bolts (T2) and 2 hard washers (T3).

17. Attach the bracket assemblies to a suitable lifting device.

    Note: The weight of the fuel pump is approximately 122 kg (269 lb).

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    Illustration 33	g06354191
    (CK) Pump Adapter (32) 558-5880 Fuel Pump Gp (34) 202-6473 Bolt (35) 5T-8224 Spacer

18. Install fuel pump (32) to pump adapter (BA) using 4 bolts (34) with 4 spacers (35).

    1. Tighten bolts (34) to 240 ± 40 N·m (177 ± 30 lb ft).
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    Illustration 34	g06354381
    (AQ) 447-7163 Fuel Transfer Pump Gp (32) 558-5880 Fuel Pump Gp (36) 6V-7673 Bolt (37) 5P-8245 Hard Washer

19. Install fuel transfer pump group (AQ) onto fuel pump group (32) with 2 bolts (36) and 2 hard washers (37).
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    Illustration 35	g06354393
    (AQ) 447-7163 Fuel Transfer Pump Gp (CN) Bracket (38) 292-3198 Hard Washer (39) 259-2627 Bolt (40) 522-6027 Bracket As (41) 323-3731 Bolt (42) 242-9985 Spacer

20. Install bracket (40) with 2 bolts (39) and 2 hard washers (38) onto bracket (CN).

    1. Tighten bolts (39) to 100 ± 20 N·m (74 ± 15 lb ft).

    2. Install bracket (40) to fuel transfer pump group (AQ) with 2 bolts (41) and 2 spacers (42).

    3. Tighten bolts (41) to 120 ± 20 N·m (89 ± 15 lb ft)

    4. Paint mark bolts (39) and bolts (41).
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    Illustration 36	g06354408
    (AR) 321-8648 Connector As (AQ) 447-7163 Fuel Transfer Pump Gp

21. Install connector assembly (AR) into fuel transfer pump (AQ).
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    Illustration 37	g06386122
    (32) 558-5880 Fuel Pump Gp (43) 560-0922 Pressure Sensor Gp (44) 238-0112 Temperature Sensor Gp

22. Install pressure sensor group (43) on the backside of fuel pump group (32).

    1. Tighten pressure sensor group (43) to 20 ± 3 N·m (15 ± 2 lb ft).

23. Install temperature sensor group (44) on the front of fuel pump group (32).

    1. Tighten temperature sensor group (44) to 45 ± 6 N·m (33 ± 4 lb ft).
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    Illustration 38	g06350476
    (45) O-ring Seal (46) 549-5638 Fuel Lines As (47) O-ring Seal

24. Apply clean, unused diesel to the threads of fuel line assembly (46), o-ring seal (45), and o-ring seal (47).

    Note: Ensure that the connection nuts are fully seated toward the ends of the fuel line before installation.

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    Illustration 39	g06353286
    (AG) 437-0014 Junction Block (AJ) 6E-1435 Spacer (AK) 431-9373 Clamp As (AL) 8T-0644 Bolt (AM) 8T-7934 Hard Washer (CM) Fuel Lines (CN) Bolt (CP) Bolt (32) 558-5880 Fuel Pump Gp (46) 549-5638 Fuel Lines As

25. Ensure that bolts (CN), fuel lines (CM), and bolts (CP) are loose.

    1. Hand thread each connection nut of fuel line assembly (46) into fuel pump (32) and junction block (AG) until the line contacts the mating surface in the fuel pump and junction box.

    2. Install clamp assembly (AK) with bolt (AL), hard washer (AM), and spacer (AJ) onto fuel line assembly (46) by hand until the clamp is in contact with the fuel line.

    3. Tighten the connection nuts of fuel line assembly (46) to 38 N·m (28 lb ft).

    4. Tighten the connection nuts of fuel line assembly (46) to 100 N·m (74 lb ft).

    5. Tighten bolts (CP) to 55 N·m (41 lb ft).

    6. Tighten bolts (CN) to 28 N·m (21 lb ft).

    7. Tighten bolt (AL) to 55 N·m (41 lb ft).

    8. Tighten the connection nuts of fuel lines (CM) to 38 N·m (28 lb ft).

    9. Tighten the connection nuts of fuel lines (CM) to 100 N·m (74 lb ft).
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    Illustration 40	g06350491
    (48) 6V-3668 Bolt (49) 5P-8245 Hard Washer (50) 115-5579 Connecting Clip Assembly (51) 566-6344 Plate As (52) 6V-3668 Bolt

    Note: Leave the bolts for this step hand tightened only.

26. Install one side of plate assembly (51) onto the fuel pump with bolt (48), washer (49), connecting clip assembly (50) and washer (49).

    1. Install the other side of plate assembly (51) with bolt (52) and washer (49).
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    Illustration 41	g06353332
    (24) 6V-5839 Washer (46) 549-5638 Fuel Lines As (51) 566-6344 Plate As (53) 566-6343 Bracket As (54) 272-2351 Bolt (55) 198-4777 Hard Washer (56) 6V-5230 Bolt (57) 2Y-5829 Nut (58) 4E-6859 Bracket As (59) 8T-7934 Hard Washer (60) 431-9373 Clamp As (61) 6V-7981 Bolt

27. Install bracket assembly (53) onto plate assembly (51).

    1. Install bolt (54) with hard washer (55) and bolt (56) with hard washer (55) through bracket assembly (53) and plate assembly (51).

    2. Finger tighten hard washer (55), nut (57), bracket assembly (58), washer (24), and nut (57) onto bolt (54).

    3. Finger tighten nut (57) with hard washer (55) onto bolt (56).

28. Finger tighten bolt (61) with hard washer (59) through clamp assembly (60) and bracket assembly (53).

    1. Finger tighten nut (57) with hard washer (59) onto bolt (61).

29. Position clamp assembly (60) and bracket assembly (53) to align with fuel line assembly (46).

    1. Tighten bolt (61) and nut (57) around fuel line assembly (46) to 7.5 ± 2.5 N·m (6 ± 2 lb ft).

    2. Tighten bolt (54) and bolt (56) with nuts (57) to 7.5 ± 2.5 N·m (6 ± 2 lb ft) to secure the plate assembly to the bracket assembly.

    3. Tighten plate assembly bolts (48) and (52) to 7.5 ± 2.5 N·m (6 ± 2 lb ft) to the fuel pump.

30. Tighten bolt (61) and nut (57) around fuel line assembly (46) to 55 N·m (41 lb ft).

    1. Tighten bolt (59) and bolt (56) with nuts (57) to a torque of 55 N·m (41 lb ft).

    2. Tighten the plate assembly bolts (48) and (52) to 100 N·m (74 lb ft) to the fuel pump.

       Note: After assembly, verify that all parts are seated fully against each other with no noticeable gaps.

       Note: Check for interference with other parts of the engine.

       Note: Verify that all high-pressure fuel line connections, clamps, bolts, and junctions are tight.

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    Illustration 42	g06353716
    (24) 6V-5839 Washer (28) 6V-4248 Bolt (44) 238-0112 Temperature Sensor Gp (51) 566-6344 Plate As (58) 4E-6859 Bracket As (62) 5P-7468 Clip (63) 5P-7469 Clip (64) 6V-1874 Grommet (65) 540-4513 Engine Harness As (66) 363-3248 Sensor Harness As (67) 6V-4249 Bolt (68) 250-7099 Mount

31. Install grommet (64) around engine harness assembly (65).

    1. Install clip (62) and clip (63) around grommet (64) and attach the clips to bracket assembly (58) with bolt (28) and washer (24).

32. Install sensor harness assembly (66) onto plate assembly (51) with bolt (67) washer (24) and mount (68).

    1. Connect sensor harness assembly (66) to temperature sensor group (44) and engine harness assembly (65).
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    Illustration 43	g06354057
    (N) 492-6182 Oil Supply Lines (BA) Pump Adapter (CQ) 445-4930 Engine Oil Filter Gp

33. Install oil supply line (N) onto engine oil filter group (CQ) and pump adapter (BA).

    1. Tighten oil supply line (N) to 140 ± 21 N·m (103 ± 15 lb ft).
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    Illustration 44	g06350906
    (32) 558-5880 Fuel Pump Gp (69) 228-7100 O-Ring Seal (70) 565-6297 Tee (71) 228-7092 O-Ring Seal (72) 228-7089 O-Ring Seal (73) 9X-2614 Connector (74) 214-7568 O-Ring Seal

34. Install tee (70) with o-ring seal (69) onto fuel pump (32).

    1. Install connector (73) with o-ring seal (74) into the tee.

    2. Install o-ring seal (72) into connector (73) and install o-ring seal (71) into the tee.
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    Illustration 45	g06350896
    (P) 437-3327 Check Valve (70) 565-6297 Tee (75) 566-7799 Hose As

35. Install hose assembly (75) into tee assembly (70) and onto check valve (P).
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    Illustration 46	g06350901
    (72) 228-7089 O-Ring Seal (73) 9X-2614 Connector (76) 6V-8634 Connector (77) 238-5080 O-Ring Seal (78) 470-8640 Hose As

36. Install hose assembly (78) and o-ring seal (72) onto connector (73).

    1. Install the hose assembly and o-ring seal (77) onto connector (76).
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    Illustration 47	g06383583
    (79) 488-1848 Cross Adapter (80) 325-7472 Pressure Sensor Gp (81) 228-7101 O-Ring Seal

37. Install pressure sensor group (80) into cross adapter (79) with o-ring seal (81).
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    Illustration 48	g06357116
    (79) 488-1848 Cross Adapter (82) 214-7568 O-Ring Seal (83) 360-3679 Connector Plug

38. Install connector plug (83) with o-ring seal (82) into cross adapter (79).
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    Illustration 49	g06351314
    (AR) 321-8648 Connector As (79) 488-1848 Cross Adapter (84) 509-5975 Hose As (85) 494-4921 Hose As (86) 332-8562 Elbow As (87) 6V-9853 Elbow

39. Install hose assembly (84) onto connector (AR) and elbow (87).

    1. Tighten hose assembly (84) to connector (AR) to 140 ± 21 N·m (103 ± 15 lb ft).

40. Install hose assembly (85) onto cross adapter (79) and elbow assembly (86).

    1. Tighten hose assembly (85) onto the cross adapter to 110 ± 17 N·m (81 ± 13 lb ft).
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    Illustration 50	g06354032
    (U) 470-8630 Hose As (T) 549-8337 Hose As (88) 281-5977 Connector As (89) 319-6213 Connector As

41. Install hose assembly (T) onto connector assembly (88).

    1. Tighten hose assembly (T) to 110 ± 17 N·m (81 ± 13 lb ft).

42. Install hose assembly (U) onto connector assembly (89).

    1. Tighten hose assembly (U) to 45 ± 5 N·m (33 ± 4 lb ft).
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    Illustration 51	g06349894
    (90) 539-3167 Manifold (91) 539-3166 Manifold (92) 6V-5842 Bolt (93) 8T-7934 Hard Washer

43. Install manifold (90) and manifold (91) with 16 bolts (92) and 16 hard washers (93).

    Reference: Refer to Disassembly and Assembly, "Air Inlet Manifold –Remove and Install"M0080117.

44. Capture a Product Status Report (PSR) of the engine ECM with current software. Flash engine ECM with the new 574-6783 Engine Software and the 569-2062 Engine Software (Aftertreatment). Capture a second Product Status Report of the engine ECM.

45. Perform a Fuel System Functional Test (FSFT) using Cat^® Electronic Technician (Cat ET) Service Tool. It is not necessary to remove any accumulator plugs to perform the Fuel System Functional Test when only the high-pressure fuel pump has been replaced.

    Note: A successful completion of the Fuel System Functional Test using Cat^® Electronic Technician (Cat ET) Service Tool must be performed.