| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A
(1) |
350-7549 | Engine Turning Tool | 1 |
| B | 294-3031 | Fuel Pump Pinch Bolt | 1 |
| C | 276-7018 | Plug/Cap Kit | 1 |
| (1) | The tooling is designed to turn the crankshaft in engines that have limited access to the flywheel housing. The tool engages all four bolt heads which are located in the front vibration damper. |
Note: All high-pressure fuel line connections to be closed with protective caps from Tooling (C)
Note: Cleanliness is a critical factor. Clean the exterior of the components before you begin the removal procedure. This action will help to prevent dirt from entering the internal mechanism.
| 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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
| NOTICE |
|---|
|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Turn the fuel supply to the OFF position.
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Illustration 1 g03827869 - Remove bolts (1), bolts (2), and guard (3).
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Illustration 2 g03828072 - Remove plug (4) and the O-ring seal.
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Illustration 3 g03828078 - Use Tooling (A) to rotate the crankshaft until the timing mark on the fuel pump is visible through the inspection hole. Install Tooling (B) and tighten to a torque of
9 ± 1 N·m (80 ± 9 lb in) .Note: Mark the damper in relation to the front timing cover as a visual reference to ensure that the crankshaft has not moved while the fuel injection pump is removed.
Note: The pump will not function while Tooling (B) is installed. Running the fuel injection pump with the tooling installed will result in pump damage and system contamination.
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Illustration 4 g03827904 - Remove bolts (8) and clamps (9).
- Remove clamps (6), hose (7), bolts (10), and tube assembly (5).
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Illustration 5 g03827925 - Disconnect hose assembly (11) and hose assembly (13).
- Remove bolt (15) and clamps (14).
- Disconnect tube assembly (16). Remove adapter assembly (12).
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Illustration 6 g03827958 - Disconnect tube assembly (17) and tube assembly (18).
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Illustration 7 g03827968 - Remove lock nuts (19) and adapter assembly (20).
- Remove nut (22), stud (23), and plate (21).
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Illustration 8 g03827992 - Disconnect harness assemblies (24).
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Illustration 9 g03828048 Note: All high-pressure fuel line connections to be closed with protective caps.
- Remove bolt (26) and clamps (25).
- Disconnect tube assembly (27).
Note: If tube assembly (27) is loosened or removed after tightening, tube assembly (27) is to be discarded and replaced.
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Illustration 10 g03828121 - Remove nut (28), nut (30), stud (29), stud (31), and bracket (32).
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Illustration 11 g03828372 - Remove bolts (33) and fuel injection pump (34).
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Illustration 12 g03828433 - Remove adapter assembly (35), elbow assembly (36), adapter assembly (37), adapter assembly (38), and adapter assembly (39).
- Install fuel injection pump (34) in the reverse order of removal.
- Tighten nut (30) and nut (22) to a torque of
28 ± 7 N·m (248 ± 62 lb in) . - Hand tighten both ends of tube assembly (27).
- Loosely install clamps (25) and bolt (26.)
- Tighten nut at pump and quill side of tube assembly (27) to a torque of
8 N·m (71 lb in) . Turn nut an additional 70°±5° clockwise. - Tighten nut at rail side of tube assembly (27) to a torque of
10 N·m (89 lb in) . Turn nut an additional 90°±5° clockwise. - Adjust clamps (25) and fully tighten bolt (26).
- Lubricate the bore of tube assembly (5) with lubricate that is being sealed.
- Tighten clamps (6) to a torque of
100 ± 5 N·m (74 ± 4 lb ft) .
- Tighten nut (30) and nut (22) to a torque of