Procedure to Install High-Pressure Fuel Pump on Certain 797F Off-Highway Truck Engines {1255, 1256} Caterpillar

Off-Highway Truck/Tractor

797F (S/N: LTZ1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

This Special Instruction describes the procedure for installing the new high-pressure fuel pump on certain 797F off-highway truck engines.

Safety Section

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

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Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

Required Parts

Table 1 contains the part numbers required for this change.

Required Tools

Removal Procedure

Note: Retain all parts and hardware that are removed, unless noted.

Note: Ensure that all the fuel system components and openings are bagged or covered during disassembly.

1. Release the residual pressure in the high-pressure fuel rail.

   Reference: Refer to Operation and Maintenance Manual, SEBU9357, "High-Pressure Fuel System - Pressure Release".

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   Illustration 1	g06386619
   (A) 438-2025 Manifold

2. Remove manifold (A).

   Reference: Refer to Disassembly and Assembly, M0080117, "Air Inlet Manifold –Remove and Install".

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   Illustration 2	g06358426
   (B) 540-4512 Engine Harness As (C) 9X-6772 Cable Strap

3. Remove cable strap (C) from engine harness assembly (B).

4. Disconnect engine harness assembly (B) from the high-pressure fuel pump system shown in Illustration 2.
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   Illustration 3	g06358448
   (C) 520-7001 Tube As (D) 500-2548 Hose As (E) 238-0112 Temperature Sensor Gp (F) 8t-0644 Bolt (G) 6V-5839 Washer (H) 250-7099 Mount (J) 8B-2026 Spacer (K) 8T-1890 Clip (L) 8T-1889 Clip (M) 353-7953 Grommet (N) 2Y-5829 Nut (P) 363-3248 Sensor Harness As (Q) 448-8988 Elbow

5. Disconnect sensor harness assembly (P) from temperature sensor (E).

6. Remove bolt (F) with washer (G), mount (H), spacer (J), washer (G), and nut (N).

   1. Remove clip (K), clip (L), and grommet (M) from hose assembly (D).

7. Remove hose assembly (D) from tube assembly (C) and elbow (Q).
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   Illustration 4	g06358483
   (E) 238-0112 Temperature Sensor Gp (R) 8T-0293 Bolt (S) 5P-8245 Hard Washer (T) 115-5579 Connecting Clip Assembly (U) 290-7493 Plate As (W) 491-3758 Fuel Pump Gp (X) 443-5167 Hose As (Y) 434-6464 Check Valve Gp

8. Remove temperature sensor (E) from the fuel pump.

9. Remove bolt (R) with hard washer (S) and clip (T).

   1. Remove bolt (R) with hard washer (S) and remove plate assembly (U) from the fuel pump.

10. Remove hose assembly (X) from fuel pump (W) and check valve (Y).
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    Illustration 5	g06358496
    (W) 491-3758 Fuel Pump Gp (Z) 494-4926 Hose As (AA) 6V-8634 Connector (AB) 468-4144 Hose As (AC) 6V-8642 Connector

11. Remove hose assembly (Z) and connector (AA) from fuel pump group (W).

    1. Remove hose assembly (AB) and connector (AC) from fuel pump group (W).
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    Illustration 6	g06358543
    (F) 8T-0644 Bolt (W) 491-3758 Fuel Pump Gp (AD) 437-0014 Junction Block (AE) 437-0032 Fuel Line (AF) 6E-1435 Spacer (AG) 8T-7934 Hard Washer (AH) 431-9373 Clamp As

12. Remove bolt (F) with washer (AG), clamp assembly (AH), and spacer (AF).

    1. Remove tube assembly (AE) from junction box (AD) and fuel pump group (W).
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    Illustration 7	g06386696
    (AJ) 494-4922 Hose As (AK) 500-2695 Check Valve Gp (AL) 463-5318 Wiring Harness (AM) 320-3061 Pressure Sensor Gp (AN) 321-8618 Connector As

13. Disconnect harness (AL) from pressure sensor (AM).

14. Remove hose assembly (AJ) from check valve (AK) and connector assembly (AN).
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    Illustration 8	g06387068
    (AP) 488-1849 Adapter As (AQ) 321-8648 Connector As (AR) 471-0389 Hose As (AS) 494-4925 Hose As

15. Remove hose assembly (AR) from connector assembly (AQ).

16. Remove hose assembly (AS) from cross adapter (AP).

    Note: Cap hose assembly (AR) and hose assembly (AS) for reuse.

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    Illustration 9	g06387193
    (G) 6V-5839 Washer (K) 8T-1890 Clip (L) 8T-1889 Clip (M) 353-7953 Grommet (AT) 6V-1820 Bolt (AU) 520-7001 Tube As (AV) 319-6236 Tee As

17. Loosen tube assembly (AU) from tee assembly (AV).

    1. Remove 3 bolts (AT) with 3 washers (G), 3 clips (K), 3 clips (L) and 3 grommets (M).

    2. Remove the tube assembly.
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    Illustration 10	g06358609
    (T1) 439-3940 Bracket As (T2) 6V-3668 Bolt (T3) 5P-8245 Hard Washer (T4) 484-3313 Fuel Pump Kit (W) 491-3758 Fuel Pump Gp (AW) Lifting Point

18. Install fuel pump kit (T4) onto fuel pump group (W)

    1. Install 2 bracket assemblies (T1) onto fuel pump group (W) at lifting points (AW) using 2 bolts (T2) and 2 hard washers (T3).

    2. Attach the bracket assemblies to a suitable lifting device.

       Note: The weight of the fuel pump is approximately 122 kg (269 lb).

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    Illustration 11	g06358625
    (AX) 447-7163 Fuel Transfer Pump Gp (AY) 2T-2991 Connector

19. Connector (AY) can be removed to provide clearance when removing fuel transfer pump (AX).
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    Illustration 12	g06358636
    (AZ) 290-7514 Bolt (BA) 7D-1649 Hard Washer (BB) 526-4590 Plate (BC) 356-9261 Bolt (BD) 2M-0849 Hard Washer

20. Remove 2 bolts (AZ) with 2 washers (BB) from plate (BB).

    1. Remove 2 bolts (BC) with 2 washers (BD) and remove the bracket.
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    Illustration 13	g06358847
    (S) 5P-8245 Hard Washer (AX) 447-7163 Fuel Transfer Pump Gp (BE) 6V-8197 Bolt

21. Remove 2 bolts (BE) with 2 hard washers (S).

    1. Remove fuel transfer pump (AX).
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    Illustration 14	g06387622
    (W) 491-3758 Fuel Pump Gp (BF) 6V-5686 Bolt (BG) 9X-8268 Washer

22. Remove 4 bolts (BF) with 4 washers (BG).

    1. Remove fuel pump (W) from the engine.
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    Illustration 15	g06387850
    (G) 6V-5839 Washer (K) 8T-1890 Clip (L) 8T-1889 Clip (N) 2Y-5829 Nut (BH) 177-4562 Grommet (BJ) 6V-6317 Bolt (BK) 6V-0826 Grommet (BL) 6V-4248 Bolt (BM) 8T-4136 Bolt

23. Remove bolt (BJ) with washer (G), clip (K), clip (L), and grommet (BH).

    1. Remove bolt (BL) with washer (G), clip (K), clip (L), and grommet (BK).

    2. Remove bolt (BM) with washer (G), clip (K), clip (L), grommet (BK), and nut (N) with washer (G).
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       Illustration 16	g06387865
       (G) 6V-5839 Washer (K) 8T-1890 Clip (L) 8T-1889 Clip (BA) 6V-1820 Bolt (BK) 6V-0826 Grommet (BN) 477-0559 Bracket As (BP) 091-9035 Spacer (BQ) 6V-4249 Bolt (BR) 132-7551 Spacer

    3. Remove bolt (BQ) with washer (G), clip (K), clip (L), grommet (BK), and spacer (BP) from bracket (BN).

    4. Remove bolt (BA) with washer (G), clip (K), clip (L), grommet (BK), and spacer (BR).
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    Illustration 17	g06359001
    (BS) 463-5318 Wiring Harness

24. Disconnect wiring harness (BS) from all the connections shown in Illustration 17.

    1. Remove and discard the wiring harness.
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    Illustration 18	g06388489
    (BQ) 6V-4249 Bolt (BT) 462-9192 Pump Drive Adapter Gp (BU) 6V-5684 Bolt (BV) 198-4766 Hard Washer

25. Remove 6 bolts (BU) and 2 bolts (BQ) with 2 hard washers (BV).

    1. Remove pump drive adapter group (BT).

Installation Procedure

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Illustration 19	g06388504
(1) 561-1137 Pump Adapter (2) 6V-5684 Bolt (3) 6V-4249 Bolt (4) 365-6813 Hard Washer (5) 165-4852 O-Ring Seal

1. Install pump adapter (1) with o-ring seal (5) using 6 bolts (2).

   1. Install 2 bolts (3) with 2 hard washers (4).
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   Illustration 20	g06389000
   (1) 561-1137 Pump Adapter (5) 3P-1156 O-Ring Seal (6) 459-6534 Filter Screen As (7) 330-3517 O-Ring Seal

2. Install o-ring seals (5) and (7) into pump adapter (1).

   1. Install filter screen assembly (6).
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   Illustration 21	g06378944
   (BW) 419-6028 Fuel Filter Gp (8) 238-5082 O-Ring Seal (9) 6V-8637 Connector

3. Install 2 connectors (9) into fuel filter housing (BW) with 2 o-ring seals (8).
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   Illustration 22	g06363738
   (DF) 419-6028 Fuel Filter Gp (8) 238-5082 O-Ring Seal (9) 6V-8637 Connector (10) 228-7100 O-Ring Seal (11) 538-9500 Adapter (12) 9X-2538 Elbow (13) 228-7092 O-Ring Seal

4. Install 2 elbows (12) with 2 o-ring seals (13) onto connectors (9).

   1. Install 2 adapters (11) with 2 o-ring seals (8) into both of the elbows.

   2. Install 2 o-ring seals (10) into both adapters (11).
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   Illustration 23	g06363774
   (10) 228-7100 O-Ring Seal (11) 538-9500 Adapter (14) 325-7471 Pressure Sensor Gp

5. Install 2 pressure sensor groups (14) into each adapter (11) with 2 o-ring seals (10).
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   Illustration 24	g06359112
   (14) 325-7471 Pressure Sensor Gp (15) 566-7826 Harness

6. Connect harness (15) to all connections shown above.
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   Illustration 25	g06378938
   (BX) 127-9323 Bracket As (16) 6V-6317 Bolt (17) 6V-5839 Washer (18) 4P-7581 Clip

7. Install clip (18) onto bracket (BX) using bolt (16) with washer (17).
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   Illustration 26	g06388604
   (G) 6V-5839 Washer (K) 8T-1889 Clip (L) 8T-1890 Clip (BH) 177-4562 Grommet (BJ) 6V-6317 Bolt (BK) 6V-0826 Grommet (BL) 6V-4248 Bolt (BY) 271-2322 Bracket As (15) 566-7826 Harness

8. Install grommet (BH), clip (K), and clip (L) around harness (15).

   1. Install bolt (BJ) with washer (G) through clip (K) and clip (L) to secure the harness to the engine.

9. Install grommet (BK), clip (K), and clip (L) around the harness.

   1. Install bolt (BL) with washer (G) through clip (K) and clip (L) to secure the harness to bracket assembly (BY).
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   Illustration 27	g06388897
   (N) 2Y-5829 Nut (G) 6V-5839 Washer (K) 8T-1889 Clip (L) 8T-1890 Clip (BM) 6V-4248 Bolt (BN) 477-0559 Bracket As (BZ) 120-4351 Plate (3) 6V-4249 Bolt (15) 566-7826 Harness (17) 6V-5839 Washer (18) 4P-7581 Clip (19) 091-9035 Spacer (20) 6V-0826 Grommet (21) 8T-1889 Clip (22) 8T-1890 Clip (23) 9X-6772 Cable Strap

10. Install grommet (BK), clip (K), and clip (L) around harness (15).

    1. Install bolt (BM) with washer (G) through clip (K) and clip (L) to secure the harness to plate (BZ).

11. Install grommet (20), clip (21), and clip (22) around the harness.

    1. Install bolt (3) with washer (17) through clip (21), clip (22), and spacer (19) to secure the harness to bracket assembly (BN).

12. Secure the harness with cable strap (23).

13. Secure the harness to clip (18) with cable strap (23).
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    Illustration 28	g06363735
    (BW) 419-6028 Fuel Filter Gp (13) 228-7092 O-Ring Seal (24) 238-5083 O-Ring Seal (25) 426-5268 Check Valve

14. Install check valve (25) into fuel filter housing (BW) with o-ring seal (24).

    1. Install o-ring seal (13) into check valve (25).
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    Illustration 29	g06379012
    (BW) 419-6028 Fuel Filter Gp (8) 238-5082 O-Ring Seal (26) 360-3682 O-Ring Plug

15. Install o-ring plug (26) with o-ring seal (8) into fuel filter housing (BW).
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    Illustration 30	g06364759
    (T1) 439-3940 Bracket As (T2) 6V-3668 Bolt (T3) 5P-8245 Hard Washer (CA) Lifting Point (27) 549-5160 Fuel Pump Gp

16. Install 2 bracket assemblies (T1) onto fuel pump group (27) at lifting points (CA) using 2 bolts (T2) and 2 hard washers (T3).

    1. Attach the bracket assemblies to a suitable lifting device.

       Note: The weight of the fuel pump is approximately 122 kg (269 lb)

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    Illustration 31	g06364749
    (CB) Protective Caps (27) 549-5160 Fuel Pump Gp (28) 6V-5553 O-Ring Seal

17. Install o-ring seal (28) onto fuel pump (27).

18. Remove and discard protective caps (CB).
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    Illustration 32	g06364655
    (27) 549-5160 Fuel Pump Gp (29) 5T-8224 Spacer (30) 202-6473 Bolt

19. Install fuel pump group (27) with 4 bolts (30) and 4 spacers (29).

    1. Tighten the bolts to 240 ± 40 N·m (177 ± 30 lb ft).
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    Illustration 33	g06379007
    (AX) 447-7163 Fuel Transfer Pump Gp (27) 549-5160 Fuel Pump Gp (31) 6V-8197 Bolt (32) 5P-8245 Hard Washer

20. Install fuel transfer pump group (AX) onto fuel pump group (27) using bolt (31) with hard washer (32).
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    Illustration 34	g06389724
    (AX) 447-7163 Fuel Transfer Pump Gp (27) 549-5160 Fuel Pump Gp (33) 564-5823 Bracket (34) 6V-8336 Bolt (35) 7D-1649 Hard Washer (36) 485-1484 Bolt (37) 344-3445 Spacer

21. Install bracket (33) onto the engine with 2 bolts (34) and 2 hard washers (35).

    1. Tighten bolts (34) to 100 ± 20 N·m (74 ± 15 lb ft).

22. Install 3 bolts (36) with 3 spacers (37) through the bracket and fuel transfer pump (AX) to fuel pump (27).

    1. Tighten bolts (36) to 120 ± 20 N·m (89 ± 15 lb ft).
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    Illustration 35	g06390239
    (E) 238-0112 Temperature Sensor Gp (27) 549-5160 Fuel Pump Gp (38) 560-0922 Pressure Sensor Gp

23. Install pressure sensor group (38) into fuel pump group (27).

    1. Tighten the pressure sensor to 20 ± 3 N·m (177 ± 27 lb in).

24. Install temperature sensor (E) into the fuel pump.

    1. Tighten the temperature sensor to 45 ± 6 N·m (33 ± 4 lb ft)
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    Illustration 36	g06364141
    (39) O-ring Seal (40) 549-5638 Fuel Lines As (41) O-ring Seal

25. Apply clean, unused diesel to the threads of fuel line assembly (40), o-ring seal (39) and o-ring seal (41).
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    Illustration 37	g06364142
    (F) 8T-0644 Bolt (AD) Junction Block (AF) 6E-1435 Spacer (AG) 8T-7934 Hard Washer (AH) 431-9373 Clamp As (CC) Fuel Lines (CD) Bolt (CE) Bolt (27) 549-5160 Fuel Pump Gp (42) 549-5638 Fuel Lines As

    Note: Ensure that bolts (CD), fuel lines (CC), and bolts (CE) are loose.

26. Hand tighten each connection nut of fuel line assembly (42) into fuel pump (27) and junction block (AD) until the line contacts the mating surface in the fuel pump and the junction block.

    1. Install clamp assembly (AH) with bolt (F), hard washer (AG), and spacer (AF) onto fuel line assembly (42) by hand until the clamp is in contact with the fuel line.

    2. Tighten the connection nuts of fuel line assembly (42) to 38 N·m (28 lb ft).

    3. Tighten bolts (CE) to 55 N·m (41 lb ft).

    4. Tighten bolts (CD) to 28 N·m (21 lb ft)

    5. Tighten bolt (F) to 55 N·m (41 lb ft).

    6. Tighten the connection nuts of fuel lines (CC) to 38 N·m (28 lb ft).
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    Illustration 38	g06364140
    (27) 549-5160 Fuel Pump Gp (32) 5P-8245 Hard Washer (43) 6V-8675 Bolt (44) 115-5579 Connecting Clip Assembly (45) 566-6344 Plate As (46) 6V-3668 Bolt

27. Install plate assembly (45) to fuel pump (27).

    1. Install bolt (43) with hard washer (32), connecting clip assembly (44), and hard washer (32).

    2. Install bolt (46) with hard washer (32).
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    Illustration 39	g06397948
    (45) 566-6344 Plate As (47) 566-6343 Bracket As (48) 272-2351 Bolt (49) 198-4777 Hard Washer (50) 6V-5230 Bolt (51) 2Y-5829 Nut

28. Install bracket assembly (47) onto plate assembly (45).

    1. Install bolt (48) with hard washer (49) and bolt (50) with hard washer (49) through bracket assembly (47) and plate assembly (45).

    2. Hand tighten hard washer (49) and nut (51) onto bolt (48).

    3. Hand tighten hard washer (49) and nut (51) onto bolt (50).
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    Illustration 40	g06397938
    (42) 549-5638 Fuel Lines As (47) 566-6343 Bracket As (51) 2Y-5829 Nut (52) 8T-7934 Hard Washer (53) 431-9373 Clamp As (54) 6V-7981 Bolt

29. Hand tighten bolt (54) with hard washer (52) through clamp assembly (53) and bracket assembly (47).

    1. Hand tighten nut (51) with hard washer (52) onto bolt (54).
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    Illustration 41	g06364133
    (42) 549-5638 Fuel Lines As (47) 566-6343 Bracket As (48) 272-2351 Bolt (49) 198-4777 Hard Washer (50) 6V-5230 Bolt (51) 2Y-5829 Nut (52) 8T-7934 Hard Washer (53) 431-9373 Clamp As (54) 6V-7981 Bolt

30. Position clamp assembly (53) and bracket assembly (47) to align with fuel line assembly (42).

    1. Tighten bolt (54) and nut (51) around fuel line assembly (42) to 8 ± 3 N·m (66 ± 22 lb in).

    2. Tighten bolt (48) and bolt (50) with nuts (51) to 8 ± 3 N·m (66 ± 22 lb in) to secure the plate assembly to the bracket assembly.

    3. Tighten plate assembly bolt (43) and plate assembly bolt (46) to 8 ± 3 N·m (66 ± 22 lb in) to the fuel pump.

31. Tighten bolt (54) and nut (51) around fuel line assembly (42) to 55 N·m (41 lb ft).

    1. Tighten bolt (48) and bolt (50) with nuts (51) to 55 N·m (41 lb ft).

    2. Tighten plate assembly bolt (43) and plate assembly bolt (46) to 100 N·m (74 lb ft).

    3. After assembly, verify that all parts are seated fully against each other with no noticeable gaps.

    4. Check for interference with other parts of the engine.

    5. Verify that all high-pressure fuel line connections, clamps, bolts, and junctions are tight.
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    Illustration 42	g06389838
    (M) 353-7953 Grommet (K) 8T-1889 Clip (L) 8T-1890 Clip (AT) 6V-1820 Bolt (G) 6V-5839 Washer (AU) 520-7001 Tube As (CF) 425-7283 Manifold (CG) 425-7283 Manifold (CH) 319-6236 Tee As

32. Install tube assembly (AU) into tee assembly (CH).

    1. Install 3 grommets (M) with 3 clips (K) and 3 clips (L) around the tube assembly.

    2. Install the tube assembly onto manifold (CF) and manifold (CG) using 3 bolts (AT) with 3 washers (G).
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    Illustration 43	g06389850
    (D) 500-2548 Hose As (E) 238-0112 Temperature Sensor Gp (F) 6V-1819 Bolt (G) 6V-5839 Washer (H) 250-7099 Mount (J) 9R-9866 Threaded Boss (K) 8T-1890 Clip (L) 8T-1889 Clip (M) 353-7953 Grommet (N) 2Y-5829 Nut (Q) 448-8988 Elbow (AU) 520-7001 Tube As (45) 566-6344 Plate As (55) 363-3248 Sensor Harness As

33. Install hose assembly (D) onto oil tube (AU) and into elbow (Q).

    1. Install grommet (M) around hose assembly (D).

    2. Install clips (K) and (L) around grommet (M).

34. Connect sensor harness assembly (55) to temperature sensor (E).

    1. Install bolt (F) with washer (G) through the sensor harness assembly, mount (H) and plate assembly (45).

    2. Install bolt (F) through threaded boss (J), clip (K), clip (L), washer (G) and nut (N).
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    Illustration 44	g06364117
    (AP) 488-1849 Adapter As (AQ) 321-8648 Connector As (13) 228-7092 O-Ring Seal (56) 228-7101 O-Ring Seal (57) 228-7091 O-Ring Seal

35. Install o-ring seal (13) into connector assembly (AQ).

36. Install o-ring seals (56) and (57) into adapter assembly (AP).
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    Illustration 45	g06389925
    (AP) 488-1849 Adapter As (58) 325-7472 Pressure Sensor Gp (59) 214-7568 O-Ring Seal (60) 360-3679 Connector Plug

37. Install pressure sensor (58) into adapter assembly (AP).

38. Install connector plug (60) with o-ring seal (59) into adapter assembly (AP).
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    Illustration 46	g06365401
    (Z) 494-4926 Hose As (AA) 6V-8634 Connector (AB) 468-4144 Hose As (AC) 6V-8642 Connector (AP) 488-1849 Adapter As (AQ) 321-8648 Connector As (AR) 471-0389 Hose As (AS) 494-4925 Hose As

39. Install hose assembly (AB) onto connector (AC).

40. Install hose assembly (Z) onto connector (AA).

41. Install hose assembly (AR) onto connector assembly (AQ).

42. Install hose assembly (AS) onto adapter assembly (AP).
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    Illustration 47	g06389956
    (13) 228-7092 O-Ring Seal (27) 549-5160 Fuel Pump Gp (59) 214-7568 O-Ring Seal (61) 228-7089 O-Ring Seal (62) 6V-8634 Connector (63) 238-5080 O-Ring Seal (64) 565-6297 Tee (65) 9X-2614 Connector

43. Install tee (64) onto fuel pump (27).

    1. Install connector (65) with o-ring seal (59) into tee (64).

    2. Install o-ring seal (61) into connector (65).

    3. Install o-ring seal (13) into tee (64).

44. Install o-ring seal (61) into connector (62) and install the connector into to the fuel pump with o-ring seal (63).
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    Illustration 48	g06363784
    (62) 6V-8634 Connector (65) 9X-2614 Connector (66) 470-8640 Hose As

45. Install hose assembly (66) onto connector (62) and connector (65).
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    Illustration 49	g06363780
    (25) 434-6464 Check Valve Gp (64) 565-6297 Tee (67) 566-4731 Hose As (68) 5P-7465 Clip (69) 5P-7464 Clip (70) 6V-7359 Grommet (71) 6V-3940 Bolt (72) 3E-4352 Hard Washer

46. Install hose assembly (67) onto tee (64) and check valve (25).

47. Install grommet (70) around hose assembly (67).

    1. Install clip (68) and clip (69) around grommet (70).

    2. Install bolt (71) with hard washer (72) through clip (68) and clip (69) to secure the assembly to the engine.
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    Illustration 50	g06366034
    (B) 540-4512 Engine Harness As (23) 9X-6772 Cable Strap

48. Connect engine harness assembly (B) to all connections shown in Illustration 50.

49. Secure engine harness assembly (B) with cable strap (23).
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    Illustration 51	g06365504
    (73) 425-7283 Manifold (74) 569-7657 Manifold (75) 6V-5842 Bolt (76) 8T-7934 Hard Washer

50. Install air manifold (73) and (74) with 16 bolts (75) and 16 washers (76).

    Reference: Refer to Disassembly and Assembly, "Air Inlet Manifold –Remove and Install"M0080117.

51. Prime the fuel system.

    Reference: Operation and Maintenance Manual, M0070546, "797F Off-Highway Truck"

52. Capture a Product Status Report (PSR) of the engine ECM with current software. Flash engine ECM with new 574-6783 engine software and 569-2062 Engine Software (Aftertreatment). Capture a second Product Status Report of the engine ECM.

53. Perform a Fuel System Functional Test (FSFT) using Cat^® Electronic Technician (Cat ET). It is not necessary to remove any accumulator plugs to perform the Fuel System Functional Test when only the high-pressure fuel pump has been replaced.

    Note: A successful completion of the Fuel System Functional Test using Cat ET must be performed.