Removal Procedure
Reference: Special Instruction, "Visual Service Procedures - Colors and Symbols" , M0066576.
Show/hide table
Table 1
| Required Tools |
| Tool |
Part Number |
Part Description |
Qty |
| A(1) |
9U-6198 |
Crankshaft Turning Tool |
1 |
| A(2) |
9U-7336 |
Housing |
1 |
| 5P-7305 |
Engine Turning Tool |
1 |
| B |
367-8608 |
Engine Timing Pin |
1 |
| C |
364-9107 |
Fuel Pump Locking Pin |
1 |
| D |
- |
Loctite 243 |
- |
Show/hide table
| (1) |
The Crankshaft Turning Tool is used on the front pulley. |
| (2) |
This Tool is used in the aperture for the electric starting motor. |
Start By:
- Remove the engine oil filter base.
Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Show/hide table
 |
|
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. |
|
Show/hide table
|
| NOTICE |
|---|
|
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. |
|
Show/hide table
|
| 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. |
|
- Turn the fuel supply to the OFF position.
- Turn the battery disconnect switch to the OFF position.
- Turn the sea water feed to the OFF position.
- For Keel cooled, drain the coolant from the circuit.
Drain the coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedures.
- Use Tooling (A) to rotate the crankshaft so that number one piston is at top dead center position . Refer to System Operation, Testing and Adjusting, "Fuel Injection Timing - Check". Use Tooling (B) to lock the crankshaft so that number one piston is at top dead center position.
Show/hide table
|
|
|
| Illustration 1 | g06267275 |
Show/hide table
|
|
|
| Illustration 2 | g06267280 |
Show/hide table
|
|
|
| Illustration 3 | g06267283 |
Show/hide table
|
|
|
| Illustration 4 | g06267285 |
Show/hide table
|
|
|
| Illustration 5 | g06267287 |
Show/hide table
|
|
|
| Illustration 6 | g06267291 |
- If necessary, remove the fuel injection pump gear and adaptor plate.
Installation Procedure
Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
- If necessary, use Tooling (A) to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Fuel Injection Timing - Check". Use Tooling (B) to lock the crankshaft so that number one piston is at top dead center position.
- If necessary, install Tooling (C) to lock the fuel injection pump in the correct position.
Show/hide table
|
|
|
| Illustration 7 | g06267292 |
Show/hide table
|
|
|
| Illustration 8 | g06267294 |
Show/hide table
|
|
|
| Illustration 9 | g06267295 |
Show/hide table
|
|
|
| Illustration 10 | g06267296 |
Show/hide table
|
|
|
| Illustration 11 | g06267297 |
Show/hide table
|
|
|
| Illustration 12 | g06267299 |
End By:
- Install the engine oil filter base.
- Replace the filters for primary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Primary (Water Separator) Element - Replace" for the correct procedure.
- Replace the filters for secondary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.
- Fill the coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct procedure.
- Turn the fuel supply to the ON position.
- Turn the battery disconnect switch to the ON position.
- Turn the sea water feed to the ON position.
- After replacement of the fuel injection pump, the fuel injection pump requires a high-pressure fuel pump calibration procedure to be performed. Refer to Troubleshooting, "Fuel Rail Pressure Problem" for the correct procedure.
