C1.5 and C2.2 Engines for Caterpillar Built Machines Caterpillar

Record the Governor Settings

If the front housing has been removed, install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install"

The setting of the low idle stop screw and the high idle stop screw must be recorded. The settings are recorded in order to ensure that the governor operation is restored.

Note: Engine speed must be recorded from the crankshaft.

1. Operate the engine until the normal operating temperature is reached.

2. Operate the engine at low idle speed. Use the electronic service tool to record the engine rpm as "Speed B".

3. Accelerate the engine to high idle. Use the electronic service tool to record the engine rpm as "Speed A".

   Note: The recorded "Speed B" will be lower than the recorded "Speed A" .

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   Illustration 1	g01494533
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   Illustration 2	g03345218
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4. Remove tamper proof caps (1).

5. Record Protrusion (X) of the high idle stop screw (4).

6. Record Protrusion (Y) of the low idle stop screw (5).

Removal of the Old Front Housing

Illustration 3	g03345219
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1. Remove fuel injection pump (4). Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove and Install" for the correct procedure.

2. Remove the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley - Remove"
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   Illustration 4	g03345222
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3. Remove front housing (5). Refer to Disassembly and Assembly, "Housing (Front) - Remove" for the correct procedure.

4. Remove the gasket (6). Ensure that the face of the front plate is clean.
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   Illustration 5	g03338638
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5. Install Tooling (E) to lever assembly (7). Tighten tooling (E) to a torque of 0.4 N·m (3.540 lb in).
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6. Remove start spring (8) and replace the start spring with Tooling (D).

7. Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install" for the correct procedure.

   Note: Do not install a gasket.

8. Install the fuel injection pump to the cylinder block. Install the original shim. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove and Install" for the correct procedure.
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   Illustration 7	g03338639
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9. Install Tooling (C) into cylinder block (9).

10. Install Tooling (B) into Tooling (C).

11. Assemble Tooling (A).

12. Install Tooling (A) into Tooling (B) until the extension on Tooling (A) touches the rack of the fuel injection pump.
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    Illustration 8	g03338640
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13. Push Tooling (A) into Tooling (B) for a further 2 mm (0.0787 inch). Lock Tooling (B) in order to retain Tooling (A) in position. Set Tooling (A) to read 2.00 ± 0.01 mm (0.0787 ± 0.0004 inch).
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    Illustration 9	g03338641
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14. Push plunger (10) of Tooling (A) several times in order to seat the rack of the fuel injection pump. When the plunger is gently released, check that Tooling (A) reads 2.00 ± 0.01 mm (0.0787 ± 0.0004 inch).

    Note: If the rack of the fuel injection pump has heavy resistance to movement, remove tooling (A). Remove the fuel injection pump. Wash the fuel injection pump with a suitable cleaner. Install the fuel injection pump. Repeat steps 12, 13 and 14.

Setting the New Front Housing

Note: Do not move the position of Tooling (A), Tooling (B), or Tooling (C) in the cylinder block.

1. Pull plunger (10) of Tooling (A) until the plunger has reached the fully out position. Use a suitable clip to retain the plunger in this position.

2. Remove the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove and Install" for the correct procedure.

3. Remove the original front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove" for the correct procedure.

4. Disassemble the original front housing. Refer to Disassembly and Assembly, "Housing (Front) - Disassemble" for the correct procedure.

5. Assemble the replacement front housing with the parts that were removed from the original front housing. Install a new fuel screw and a new locknut. Refer to Disassembly and Assembly, "Housing (Front) - Assemble" for the correct procedure.

6. Remove Tooling (E) from the original front housing. Install Tooling (E) to the lever assembly of the replacement front housing. Tighten Tooling (E) to a torque of 0.4 N·m (3.5 lb in).

7. Install the replacement front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install" for the correct procedure.

   Note: Do not install a gasket.

8. Install the fuel injection pump to the cylinder block. Install the original shim. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove and Install" for the correct procedure.

9. Remove the clip from plunger (10) of Tooling (A).

Setting the Fuel Screw

Illustration 10	g03338642
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Illustration 11	g03338643
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1. Release the plunger on Tooling (A). Do not move the position of Tooling (A), Tooling (B), or Tooling (C) in the cylinder block.

2. Use a ring spanner (Box wrench) (12) to retain the locknut of the fuel screw in position.

3. Use an allen wrench (11) to rotate the allen head screw. Observe the reading on the dial indicator. Adjust the allen head screw until the indicator reads 2.00 ± 0.01 mm (0.0787 ± 0.0004 inch).

4. Tighten the locknut to a torque of 6 N·m (55 lb in) in order to retain the allen head screw in position. The fuel screw is now set.

5. Ensure that the reading of Tooling (A) is 2.00 ± 0.01 mm (0.0787 ± 0.0004 inch).

Final Installation of the New Front Housing

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Illustration 12	g01495413
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1. Remove Tooling (A) and Tooling (B).

2. Remove Tooling (C).

3. Remove the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove and Install" for the correct procedure.

4. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove" for the correct procedure.
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   Illustration 13	g03338638
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5. Remove Tooling (E) from lever assembly (7).
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   Illustration 14	g03345222
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6. Install a new gasket (6). Ensure that the gasket is clean and free from damage.

7. Install the replacement front housing (5) Refer to Disassembly and Assembly, "Housing (Front) - Install" for the correct procedure.
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   Illustration 15	g01494533
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   Illustration 16	g03345218
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8. Set the Protrusion (X) of the high idle stop screw (2) to the same dimensions as the stop screws on the original front housing.

9. Set the Protrusion (Y) of the low idle stop screw (3) to the same dimensions as the stop screws on the original front housing.

10. Install the fuel injection pump to the cylinder block. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove and Install" for the correct procedure.

11. Start the engine and allow the engine to reach normal operating temperature.

12. Run the engine at low idle speed. Use the electronic service tool to check if the engine rpm is the same as "Speed B".

13. Run the engine at high idle speed. Use the electronic service tool to check if the engine rpm is the same as "Speed A".

    Note: The recorded "Speed A" will be higher than the recorded "Speed B".

    Note: If "Speed A" does not match the high idle speed or "Speed B" does not match the low idle speed, contact Global Technical Support.

14. Ensure correct operation of the engine.
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    Illustration 17	g03338646
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15. Install tamper proof caps (1) to the high idle screw (2). Install the tamper proof cap (not shown) to fuel screw (13).

    Note: Care should be taken when the tamper proof cap is installed to the fuel screw.