325F Excavator Engine Supplement Caterpillar

Removal Procedure

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.

1. The Electronic Control Module (ECM) can be a fuel cooled ECM or air cooled ECM. The removal procedure is similar for a fuel cooled ECM or air cooled ECM.

2. Turn the battery disconnect switch to the OFF position.

3. Turn the fuel supply to the OFF position.

4. If necessary, remove the secondary filter assembly. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure.

5. If necessary, remove the primary fuel filter assembly. Refer to Disassembly and Assembly, "Water Separator and Fuel Filter (Primary) - Remove and Install" for the correct procedure.

6. If necessary, remove the dipstick tube assembly. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install" for the correct procedure.
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   Illustration 1	g03738323
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   Illustration 2	g03738325
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   Illustration 3	g03738326
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7. Cut cable strap (2) and cable strap (6) from plastic tube assembly (1).

8. Remove plastic tube assembly (1) from the crankcase breather canister. Refer to Disassembly and Assembly, "Crankcase Breather - Remove" for the correct procedure.

9. Disconnected harness assembly (3) from the fuel temperature sensor. Refer to Disassembly and Assembly, "Fuel Temperature Sensor- Remove and Install" for the correct procedure.

10. Disconnected harness assembly (4) from the engine oil pressure sensor. Refer to Disassembly and Assembly, "Engine Oil Pressure Sensor - Remove and Install" for the correct procedure.

11. Disconnect the harness assembly from crankshaft position sensor (5) (not shown). Refer to Disassembly and Assembly, "Crankshaft Position Sensor - Remove and Install" for the correct procedure.

12. Cut cable straps (7) from harness assembly for camshaft position sensor (8) (not shown). Disconnect the harness assembly from camshaft position sensor (9) (not shown). Refer to Disassembly and Assembly, "Camshaft Position Sensor - Remove and Install" for the correct procedure.

13. Disconnect harness assembly (9) from atmospheric pressure sensor (10). Refer to Disassembly and Assembly, "Atmospheric Pressure Sensor - Remove and Install" for the correct procedure.
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    Illustration 4	g03738863
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14. Disconnect plastic tube assembly (11) and plastic tube assembly (14) from tube assembly (12). Use Tooling (A) to plug the plastic tube assemblies and to cap the tube assembly.

15. Use a suitable tool in Position (X) to hold and disconnect hose assembly (16) from connection on tube assembly (13). Remove O-ring seal (17) (not shown). Use Tooling (A) to plug the hose assembly and to cap the tube assembly.

16. Use a suitable tool in Position (X) to hold tube assembly (12) as nut (15) is loosened. Remove bolt (13) from tube assembly (12).

17. Remove tube assembly (12) from the bracket and the cylinder head.

18. Remove O-ring seal (18) (not shown) from tube assembly (12).

19. Use Tooling (A) to plug the cylinder head and to cap the tube assembly.
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    Illustration 5	g03738899
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20. Cut cable straps (19) from engine harness assembly. Ensure that all the cable straps are removed.

21. Remove bolt (24) from ECM plug (20).

22. Loosen the allen head bolt (22) that secures ECM plug (20) for engine harness assembly (26) to ECM (28).

23. Position engine harness assembly (26) away from the ECM.

24. Remove bolt (25) from Original Equipment Manufacture (OEM) plug (21).

25. Loosen the allen head bolt (23) that secures OEM plug (21) for the OEM harness assembly (27) to ECM (28).

26. Position OEM harness assembly (27) away from the ECM.
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    Illustration 6	g03738900
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27. Make temporary identification marks on the plastic tube assembly (37) and plastic tube assembly (36) for installation purposes.

28. Place a suitable container below the ECM (28) to catch any fuel that might be spilled.

29. Disconnect plastic tube assembly (37) and plastic tube assembly (36). Drain the fuel from ECM (28).

30. Use Tooling (A) to plug plastic tube assembly (37) and plastic tube assembly (36).

31. Use Tooling (A) to cap connections on the ECM for plastic tube assemblies.

32. Remove plastic tube assembly (33) and plastic tube assembly (34) from clips (35).

33. Disconnect the plastic tube assembly from valve (31) Use Tooling (A) to cap connection on valve (31) and the plastic tube assembly.

34. Remove bolt (29) spacer (30) for valve (31).

35. Remove bolts (38) and washer (39) (not shown) from bracket (32) and from ECM (28). Ensure that earth strap (40) is not damaged as the bolts are removed. Support the weight of the ECM as the bolts are removed.

    Note: Note the orientation and position of the brackets

36. Remove bracket (32) and ECM (28) from the engine.

    Note: When removing the bolts from the ECM, ensure that the fuel injection line from the fuel injection pump to the fuel manifold is not damaged.

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    Illustration 7	g03738901
    Fuel cooled ECM

37. If necessary, follow Step 37.a through Step 37.d to disassemble ECM (28).

    1. Remove isolation mount (45), isolation mount (47), and limit sleeves (46).

    2. If necessary, remove connection (41) and connection (44) from ECM (28).

    3. If necessary, remove O-ring seal (42) and O-ring seal (43) from the connections.

    4. Use Tooling (A) to plug ECM (28). Use Tooling (A) to cap the connection (41) and connection (44).
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    Illustration 8	g03738902
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38. If necessary, remove spacers (48) from cylinder block (49).

Installation Procedure

1. The Electronic Control Module (ECM) can be a fuel cooled ECM or air cooled ECM. The installation procedure is similar for a fuel cooled ECM or air cooled ECM.

2. If a replacement ECM is installed, the replacement ECM must be programmed with the correct information. Refer to Troubleshooting Guide, "Replacing the ECM" and refer to Troubleshooting Guide, "Flash Programming" for the correct procedure.

3. Ensure that the electronic control module is clean and free from damage. If necessary, replace the electronic control module.
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   Illustration 9	g03738902
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4. If necessary, install spacers (48) to cylinder block (49). Tighten the spacers to a torque of 44 N·m (32 lb ft).
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   Illustration 10	g03738901
   Fuel cooled ECM

5. If necessary, follow Step 5.a through Step 5.d to assemble ECM (28).

   1. Remove caps from connection (41). Install new O-ring seal (42) to the connection.

   2. Remove caps from connection (44). Install a new O-ring seal (43) to the connection.

   3. Remove plugs from ECM (28). Install connection (41) and connection (44) to the ECM. Tighten the connections to a torque of 18 N·m (159 lb in).

   4. Install isolation mount (45), isolation mount (47), and limit sleeves (46) to ECM (28).
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   Illustration 11	g03738900
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6. Position bracket (32) onto ECM (28). Ensure that the bracket is correctly orientated.

7. Position bracket (32) and ECM (28) onto the cylinder block. Support the weight of the ECM as the bolts are installed.

   Note: Ensure that the fuel injection line is not damaged during the installation of the bracket.

8. Install bolts (38) and washer (39) (not shown) to bracket (32) and to ECM (28). Ensure that earth strap (40) is correctly positioned between the bolts and the washers. Hand tighten the bolts.

9. Tighten bolts (38) to a torque of 22 N·m (195 lb in).

10. Install spacer (30) and bolt (29) to valve (31). Tighten the bolt to a torque of 9 N·m (80 lb in).

11. Remove caps connection on valve (31) and the plastic tube assembly. Connect the plastic tube assembly to valve (31)

12. Install plastic tube assembly (33) and plastic tube assembly (34) to clips (35).

13. Remove caps connections on the ECM for plastic tube assemblies. Remove plugs from plastic tube assembly (37) and plastic tube assembly (36).

14. Connect plastic tube assembly (37) and plastic tube assembly (36) to connections on ECM (28).
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    Illustration 12	g03738899

15. Position the OEM harness assembly (27) onto ECM (28).

16. Tighten the allen head bolt (23) that secures OEM plug (21) for the OEM harness assembly (27) to ECM (28). Ensure that the OEM wiring harness is correctly routed.

    Note: Care must be taken to avoid damage to the connector pins during installation of the harness assembly.

17. Install bolt (25) to OEM plug (21). Hand tighten the bolt.

18. Tighten allen head bolt (23) to a torque of 6 N·m (53 lb in).

    Tighten bolt (25) to a torque of 6.5 N·m (59 lb in).

19. Position engine harness assembly (26) onto ECM (28). Ensure that the engine wiring harness is correctly routed.

20. Tighten the allen head bolt (22) that secures ECM plug (20) for engine harness assembly (26) to ECM (28).

    Note: Care must be taken to avoid damage to the connector pins during installation of the harness assembly.

21. Install bolt (24) to ECM plug (20). Hand tighten the bolt.

22. Tighten allen head bolt (22) to a torque of 6 N·m (53 lb in).

    Tighten bolt (24) to a torque of 6.5 N·m (59 lb in).

23. Install new cable straps (19) to engine harness assembly.

    Note: Ensure that the cable straps meet OEM specifications.

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    Illustration 13	g03738863
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24. Remove the plug from cylinder head and to the cap from tube assembly (12). Install a new O-ring seal (18) (not shown) to the tube assembly.

25. Install tube assembly (12) to the bracket and the cylinder head. Install bolt (13) to the tube assembly hand tight.

26. Use a suitable tool in Position (X) to hold tube assembly (12) as nut (15) is tightened hand tight.

27. Tighten bolt (13) to a torque of 22 N·m (195 lb in).

28. Use the suitable tool to hold tube assembly (12) in Position (X). Tighten nut (15) to a torque of 28 N·m (248 lb in). Ensure that the tube assembly is not strained as the nut is tightened.

29. Remove the plug from plastic tube assemblies and the cap from tube assembly (12). Connect plastic tube assembly (11) and plastic tube assembly (14) to the tube assembly

30. Remove the plug from hose assembly (16) and remove the cap from tube assembly (12).

31. Install a new O-ring seal (17) (not shown). Ensure that the O-ring seal is correctly seated into the recess of the tube assembly.

32. Connect hose assembly (16) from connection on tube assembly (13) hand tight.

33. Use the suitable tool to hold tube assembly (12) in Position (X). Tighten the nut for hose assembly to a torque of 43 N·m (32 lb ft).
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    Illustration 14	g03738326
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    Illustration 16	g03738323
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34. Connect harness assembly (9) to atmospheric pressure sensor (10). Refer to Disassembly and Assembly, "Atmospheric Pressure Sensor - Remove and Install" for the correct procedure.

35. Connect the harness assembly to camshaft position sensor (8). Refer to Disassembly and Assembly, "Camshaft Position Sensor - Remove and Install" for the correct procedure.

36. Install new cable straps (7) to harness assembly for camshaft position sensor (8).

    Note: Ensure that cable straps meet the OEM specification.

37. Connect the harness assembly from crankshaft position sensor (5) (not shown). Refer to Disassembly and Assembly, "Crankshaft Position Sensor - Remove and Install" for the correct procedure.

38. Connected harness assembly (4) to the engine oil pressure sensor. Refer to Disassembly and Assembly, "Engine Oil Pressure Sensor - Remove and Install" for the correct procedure.

39. Connected harness assembly (3) to the fuel temperature sensor. Refer to Disassembly and Assembly, "Fuel Temperature Sensor- Remove and Install" for the correct procedure.

40. Install plastic tube assembly (1) to the crankcase breather canister. Refer to Disassembly and Assembly, "Crankcase Breather - Remove" for the correct procedure.

41. Install new cable strap (2) and cable strap (6) to plastic tube assembly (1).

    Note: Ensure that cable straps meet the OEM specification.

42. If necessary, install the dipstick tube assembly. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install" for the correct procedure.

43. If necessary, install the primary fuel filter assembly. Refer to Disassembly and Assembly, "Water Separator and Fuel Filter (Primary) - Remove and Install" for the correct procedure.

44. If necessary, install the secondary filter assembly. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure.

45. Turn the fuel supply to the ON position.

46. Turn the battery disconnect switch to the ON position.

47. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.