Removal Procedure
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 150-3993 | Timing Pin (2) | 1 |
| ( 2 ) | Tool (A) is required in order to remove Delphi fuel injection pumps. |
Start By:
- Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".
- Remove the fuel injection nozzles. Refer to Disassembly and Assembly, "Fuel Injection Nozzles - Remove".
- Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".
- Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove".
- Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".
Reference:
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
| 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, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
- Remove the throttle linkage (1) from the fuel injection pump. Remove the electrical connection (2) for the fuel shutoff solenoid.
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| Illustration 1 | g00799335 |
Delphi DP200 Fuel injection pump | |
- Ensure that the No. 1 cylinder is on the top center position on the compression stroke. Refer to the Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".
- Loosen the locking screw (3) and pull out the spacer (4) on the fuel injection pump body. Tighten the locking screw to a torque of 12 N·m (9 lb ft).
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| Illustration 2 | g00292837 |
Typical example (A) Unlocked position (B) Locked position | |
- Slowly rotate the crankshaft until hole (8) in the timing gear and hole (9) in the hub are in alignment with hole (10) in the fuel injection pump body .
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| Illustration 3 | g00799345 |
Typical example | |
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| Illustration 4 | g00799347 |
Typical example | |
Note: Do not remove hub nut (5) from the shaft of the fuel injection pump. The hub of the fuel injection pump is installed in the correct position from the factory in order to ensure proper timing. If hub nut (5) is removed and the hub is removed, the hub will need to be accurately installed on the shaft of the fuel injection pump by the use of special equipment. Refer to your Caterpillar Dealer for more information.
Note: Do not release torx screws (6) (if equipped). If the torx screws are released and the timing plate is moved, the timing position that is set at the factory will be lost. If the torx screws are released, the number 1 cylinder must be set to the top center position on the compression stroke before the torx screws are tightened.
- Install Tool (A) through hole (8) in the timing gear and hole (9) in the hub. Push Tool (A) into position in hole (10) in the fuel injection pump body. If Tool (A) can be fully seated, the fuel injection pump timing is correct. No resistance should be felt when the timing pin is inserted into hole (10) of the fuel injection pump body.
Note: The location of Tool (A) forthe Delphi fuel injection pump is located toward the bottom of the fuel injection pump body.
- Remove four bolts (6). Remove timing gear (7) from the fuel injection pump shaft.
- Remove three nuts (11) and remove fuel injection pump (12) from the engine.
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| Illustration 5 | g00805098 |
Delphi DP200 Fuel injection pump | |
- Remove the O-ring seal from fuel injection pump (12) .