C175-16 and C175-20 Locomotive Engines Caterpillar


Fuel Pump (High Pressure) - Remove and Install

Usage:

C175-16 3B9

Removal Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
A(1)  439–3940  Bracket Ast 
6V-3668 12 MM Bolt 
5P-8245 Hard Washer 
484-3313  Fuel Pump Kit 
(1) Use one to remove the fuel pump from the EPG engine.

Start By:

  1. Remove the fuel transfer pump.


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.


------ WARNING! ------

This fuel system may contain high-pressure fuel for extended periods after engine shutdown. Do not open the high-pressure fuel system without first releasing the high-pressure fuel from the system. Refer to the Operation and Maintenance Manual, "High-Pressure Fuel System - Pressure Release" to properly release fuel pressure. Exposure to high-pressure fuel may result in personal injury.




    Illustration 1g06261853

  1. Remove air manifold (1). Refer to Disassembly and Assembly, "Air Inlet Manifold - Remove and Install" to remove air manifold (1).


    Illustration 2g06261967

  2. Disconnect hose assemblies (2) and (3). Disconnect harness assembly (4).


    Illustration 3g06261968

  3. Disconnect hose assembly (5) and harness assembly (8). Remove fuel pressure sensor (6) and fuel temperature sensor (7).

    Note: Discard the fuel pressure sensor (Rail) after use. Use new fuel pressure sensor (Rail) for installation.



    Illustration 4g06262676

  4. Remove clamp assembly (10) and remove tube assembly (9).


    Illustration 5g06261977


    Illustration 6g06261982

  5. Disconnect hose assembly (13).

  6. Attach Tooling (A) and a suitable lifting device to high-pressure fuel pump (11). The weight of high-pressure fuel pump (11) is approximately 120 kg (265 lb).

  7. Remove four bolts (12).

  8. Rotate high-pressure fuel pump (11) as shown in Illustration 6 and add another Tooling (A).

  9. Remove high-pressure fuel pump (11).

Installation Procedure

  1. Install high-pressure fuel pump (9) in the reverse order of removal.

    1. Tighten fuel pressure sensor (6) to a torque of 45 ± 6 N·m (33 ± 4 lb ft) with a 27 mm (1.0 inch) deep socket or crowfoot.

    2. Tighten fuel temperature sensor (7) to a torque of 20 ± 3 N·m (177 ± 27 lb in).

    3. Lubricate O-ring seals of tube assembly (9). Connect tube assembly (9) and hand tighten nut (10).

    4. Install clamp assembly (10). Hand tighten the bolt on clamp assembly (10).

    5. Tighten the connection nuts of tube assembly (9) to a torque of 38 N·m (28 lb ft). Tighten the connection nuts to a final torque of 100 N·m (74 lb ft).

    6. Tighten the bolt on clamp assembly (10) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

  2. Following repairs to the high-pressure fuel system, accumulator plugs on opened cylinders should be removed. A successful completion of the "Fuel Systems Function Test (FSFT)" using CATET must be performed. Upon completion of the FSFT, accumulator plugs are to be reinstalled.

    1. After replacing the high-pressure fuel pump, perform a fuel system functional test. 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.

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