C175-16 Locomotive Engine Caterpillar

Removal Procedure

Start By:

1. Remove the air inlet manifold.
2. Remove Install the flow limiters.

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Do not open the high pressure fuel system without allowing the fuel system to purge. After the engine has shut down, allow the fuel system to purge for ten minutes. This operating fuel system contains high pressure. Exposure to high pressure fuel can result in personal injury.

Note: Do not remove all the quills at one time. To maintain alignment, leave a minimum of two quills attached to the fuel rail at all times. If necessary, replace with new quill.

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Illustration 1	g01285837

1. Remove bolt (1) and the clamp from tube assembly (2) .

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Illustration 2	g03348199

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Illustration 3	g01443406

Note: Use Tooling (A) to cap tube assemblies, fittings, ports, and any opening in the fuel system to prevent contamination.

2. Disconnect tube assembly (3) and remove the bolts on tube assembly (2) . Remove bolts (5) . Disconnect tube assembly (4) . Remove tube assembly (2) and the O-ring seals. Remove bolts (6) .

   Note: If necessary, remove secondary fuel filter lines in order to remove tube assembly (2) .

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Illustration 4	g01285008

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Illustration 5	g01822394

3. Remove bolts (9) . Remove bolts (10) and bolts (11) . Repeat for the opposite side.

4. Remove tube assembly (7) . Remove tube assembly (8) and the O-ring seal.

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Illustration 6	g01822395

5. Attach a suitable lifting device to fuel rail (13) . The weight of fuel rail (13) is approximately 60 kg (131 lb). Remove bolts (12) . Remove fuel rail (13) .

6. Place the high-pressure fuel rail on a clean surface. Support the rail so the weight is not resting on the quills. All openings should be capped or plugged to prevent contamination.

7. Repeat Steps 5 and 6 for the opposite side.

Installation Procedure

Note: Carefully remove Tooling (A) to prevent contamination.

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Illustration 7	g01822395

1. Attach a suitable lifting device onto fuel rail (13) . The weight of fuel rail (13) is approximately 60 kg (131 lb). Install fuel rail (13) . Install bolts (12) .

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Illustration 8	g01443632

2. Tighten bolts (12) in the sequence that is shown in Illustration 8. Tighten bolts (12) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

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Illustration 9	g01822394

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Illustration 10	g01285008

3. Install the new O-ring seals. Lubricate the ends of tube assembly (8) and the O-ring seals with clean engine oil. Install new bolts (9) and the washers. Hand tighten new bolts (9) evenly to assemble tube assembly (8) to prevent cutting or damage to the O-ring seals. Install tube assembly (7) . Install and bolts (10) and (11) tighten by hand. Tighten new bolts (9) evenly to a torque of 20 N·m (177 lb in).

   Note: Do not rotate new bolts (9) more than 90 degrees at a time.

4. Tighten new bolts (9) evenly to a torque of 40 ± 5 N·m (30 ± 4 lb ft).

   Note: Do not rotate new bolts (9) more than 45 degrees at a time.

5. Tighten bolts (10) and (11) to a torque of 40 ± 10 N·m (30 ± 7 lb ft).

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Illustration 11	g01443406

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Illustration 12	g01822393

Note: If necessary, secondary fuel filter lines may need installed after tube assembly (2) has been installed. Do not attempt to push the flanges past O-ring seals by hand in order to prevent cutting or damage.

6. Install the new O-ring seals into the pump outlet, the inlet, and the junction block. Lubricate O-ring seals and the end of tube assemblies (2) and (4) with clean engine oil.

   Note: Do not rotate the bolts in tube assembly (2) more than 90 degrees at a time.

   1. Install new bolts (5) and the washers. Hand tighten new bolts (5) evenly to engage tube assemblies (2) and (4) to prevent damage of the O-ring seal.

   2. Install bolts (6) and tighten by hand. Hand tighten bolts (5) evenly. Tighten bolts (6) evenly to a torque of 20 N·m (15 lb ft).

   3. Tighten new bolts (5) evenly to a torque of 20 N·m (177 lb in).

   4. Tighten bolts (6) evenly to a final torque of 55 ± 10 N·m (41 ± 7 lb ft).

   5. Tighten bolts (5) evenly to a final torque of 40± 10 N·m (30± 7 lb ft).

Note: Do not rotate the bolts in tube assembly (2) more than 45 degrees at a time.

7. Tighten the bolts in tube assembly (2) evenly to a torque of 40 N·m (30 lb ft).

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Illustration 13	g01285837

8. Install the bracket, the clamp, and bolt (1) onto tube assembly (2) . Use the bracket to adjust the position of the clamp and bolt (1) for alignment to tube assembly (2) .

9. Repeat this process on the opposite side.

End By:

1. Install the flow limiters.
2. Install the air inlet manifold.