- Engine:
- C7 (S/N: C7S1-UP)
- C9 (S/N: MFF1-UP; C9S1-UP)
Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.
Before replacing the C7 or C9 high-pressure fuel pump, follow the instructions that are listed below.
Note: Failure to follow these procedures may result in a damaged pump housing and leaking fuel line.
 | |
| Illustration 1 | g02242333 |
(1) Previous location of the timing pin | |
 | |
| Illustration 2 | g02242334 |
(2) Current location of the timing pin | |
Note: The location of the timing pin on the high-pressure fuel pump has changed. On the previous design of the pump, the timing pin was located at the bottom of the lift pump. On the new design of the pump, the timing pin is located on the side of the fuel pump housing.
Safety
| NOTICE |
|---|
Contact with high pressure fuel may cause personal injury or death. Wait 60 seconds after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines. |
| 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. 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. |
 |
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. |
 |
Finding Top Center for the No. 1 Piston
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Name | Qty |
| A | 139-7063 | Timing Pin Adapter | 1 |
| B | 136-4632 | Timing Pin | 1 |
| C | 208-0888 | Engine Turning Tool | 1 |
 | |
| Illustration 3 | g01167315 |
Flywheel housing (1) Timing hole | |
- Remove the plug from timing hole (1) and install Tool (B) in the timing hole on the flywheel housing. Tool (C) can be used for turning the flywheel in the flywheel housing. Turn the flywheel in the direction of engine rotation. The direction of engine rotation is counterclockwise, as the engine is viewed from the flywheel end. Turn the flywheel until the timing pin engages with the threaded hole in the flywheel.
Note: If the flywheel is turned beyond the point of engagement, the flywheel must be turned in the direction that is reverse of normal engine rotation. Turn the flywheel by approximately 30 degrees. Then turn the flywheel in the direction of normal rotation until the timing pin engages with the threaded hole. This procedure eliminates the backlash from the gears when the No. 1 piston is at the top center position.
Removing the Air Compressor
|
Do not disconnect the air lines until the air pressure in the system is at zero. If hose is disconnected under pressure it can cause personal injury. |
|
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
| 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. |
- Ensure that the No. 1 cylinder is at top dead center.
- Remove the air pressure from the air tank.
- Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".
- Disconnect tube assembly (1), tube assembly (2), tube assembly (3), and tube assembly (4) .
 | |
| Illustration 4 | g01356642 |
- Remove clamp assembly (5) .
- Attach a suitable lifting device onto air compressor (6). The weight of air compressor (6) is approximately 32 kg (70 lb).
 | |
| Illustration 5 | g01356660 |
- Remove bolts (9) and cover (10). Ensure that the timing mark on the crankshaft of the compressor is positioned between the timing marks on the housing for the compressor. Reinstall cover (10) and bolts (9). Remove bolts (7). Remove bracket (8) .
 | |
| Illustration 6 | g01356872 |
 | |
| Illustration 7 | g01271799 |
- Remove bolts (11). Remove the air compressor and the O-ring seal from the engine.
 | |
| Illustration 8 | g01356874 |
Removing the Old High-Pressure Fuel Pump
| Required Tools | |||
| Tool | Part Number | Description | Qty |
| A | 267-2647 | Stop Plug | 1 |
| B | 9S-4180 | Plug | 1 |
- Ensure that the No. 1 cylinder is at top dead center. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".
Note: Cleanliness is a critical factor. Before you begin the removal procedure, thoroughly clean the exterior of the components. This action will help to prevent dirt from entering the internal mechanism.
- Remove Tooling (B) and install Tooling (A) .
 | |
| Illustration 9 | g01365114 |
- Disconnect harness assemblies (1) .
 | |
| Illustration 10 | g01365119 |
- Disconnect tube assemblies (2) and (3) .
- Remove bolts (4) and remove bolts (6) .
 | |
| Illustration 11 | g01365116 |
 | |
| Illustration 12 | g01365117 |
- Remove bracket (5) .
- Remove nuts (8) and remove bracket (7) .
- Disconnect fitting (9) .
 | |
| Illustration 13 | g01365113 |
- Remove bolts (11) and remove the fuel injection pump (10) .
 | |
| Illustration 14 | g01365111 |
Installing the New High-Pressure Fuel Pump
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
| Required Parts | |||
| Item | Qty | Part Number | Description |
| 1 | 1 | 294-3031 | Special Bolt |
| 2 | 1 | 364-3761 | Instruction Tag |
| 3 | 1 | 358-0950 | Fuel Injection Pump Gp |
| 14 | 1 | 228-7089 | O-Ring Seal |
| 15 | 1 | 364-0628 | Special Plug |
| 16 | 1 | 364-9640 (C7) or 310-6031 (C9) |
Fuel Lines Kit |
- Ensure that the No. 1 cylinder is at the top dead center.
- Replace the discarded fuel line tube assembly with the 310-6031 Fuel Lines Kit for C9 engines. For C7 engines, replace with the 364-9640 Fuel Lines Kit . The clamp, grommet, and new fuel line that is supplied with the new fuel line kit must be used as replacements for the original parts.
- Position new fuel pump (3) and install bolts (4) .
 | |
| Illustration 15 | g02242274 |
Note: Ensure that the special bolt (1) and the instruction tag (2) are installed prior to installation of the fuel injection pump.
 | |
| Illustration 16 | g02242317 |
- Connect fitting (5) .
 | |
| Illustration 17 | g02248115 |
- Position bracket (6) and install nuts (7) .
 | |
| Illustration 18 | g02248174 |
 | |
| Illustration 19 | g02248240 |
- Position bracket (9) and install bolts (8) .
- Install bolts (10) .
- Connect tube assemblies (13) and (12) .
 | |
| Illustration 20 | g02248275 |
- Connect harness assemblies (11) .
- Remove the special bolt (1) and the instruction tag (2) and install the O-ring seal (14) and the special plug (15) .
 | |
| Illustration 21 | g02242297 |
Installing the Air Compressor
- Ensure that the No. 1 cylinder is at the top center compression stroke.
- Attach a suitable lifting device onto air compressor (6). The weight of air compressor (1) is approximately 32 kg (70 lb). Position the O-ring seal and air compressor (1) onto the engine.
 | |
| Illustration 22 | g02243923 |
Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal.
- Install bolts (2) .
 | |
| Illustration 23 | g02243924 |
- Remove bolts (6) and cover (5). Ensure that the timing mark on the crankshaft of the compressor is positioned between the timing marks on the housing for the compressor. Install cover (5) and bolts (6). Install bracket (4). Install bolts (3) .
 | |
| Illustration 24 | g02243925 |
| | |
| Illustration 25 | g01271799 |
Timing marks. | |
- Connect tube assembly (10), tube assembly (9), tube assembly (8), and tube assembly (7) .
 | |
| Illustration 26 | g02243927 |
Note: Removal of the timing pin is necessary prior to connecting tube assembly (4) .
- Install clamp assembly (11) .
- Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change.".
Testing the Fuel System
Connect Caterpillar Electronic Technician (ET). Perform a "Fuel System Fuctional Test" and a "Fuel System Verification Test".