D348 VEHICULAR ENGINE Caterpillar


Fuel Injection Pump Housing

Usage:



Remove Fuel Injection Pump Housing, Governor And Fuel Filter Housing As A Unit

preparatory step:

a) remove fuel injection lines

1. Rotate the crankshaft to top dead center compression stroke No. 1 piston. See LOCATING TOP DEAD CENTER COMPRESSION POSITION FOR NO. 1 PISTON in TESTING AND ADJUSTING.

2. Disconnect governor control linkage from the governor. Remove the governor control channel assembly (1).

3. Remove the fuel ratio control sensing line (2). Disconnect wiring from fuel shutoff solenoid (if so equipped).

4. Remove the governor-to-right aftercooler housing mounting bracket (3). Remove the three fuel injection pump housing-to-right cylinder head mounting brackets (4).

5. Disconnect fuel filter housing drain line from the fuel filter housing. Remove the fuel inlet line and fuel return line. Remove the two oil drain elbow-to-cylinder block mounting bolts (5). Loosen the aftercooler vent line fittings and rotate line cear of fuel filter housing.

6. Remove the two turbocharger oil drain lines. Remove the variable timing unit cover. Remove the drive gear (6), retainer, mounting bolts and lock.

7. Remove the two governor-to-left cylinder head mounting bolts from bracket at rear of governor. Remove the seven fuel injection pump housing-to-cylinder block mounting bolts.

NOTE: Observe the location of the ground body mounting bolts. Install these bolts back in their original location when installing fuel injection pump housing.

8. Remove two of the fuel injection pump mounting bolts and install two 3/8"-16NC forged eyebolts.

9. Attach a hoist and move the assembly forward to clear the O-ring seals at rear of pump housing. Remove the fuel injection pump housing, governor and fuel filter housing as a unit - weight 260 lbs. (118 kg).

Install Fuel Injection Pump Housing, Governor And Fuel Filter Housing As A Unit

1. Attach a hoist and position the fuel injection pump housing, governor and fuel filter housing on the engine. Move the assembly toward the rear of engine to seat the O-ring seals in cylinder block.

2. Remove the two forged eyebolts and install the two fuel injection pump retaining bolts.

3. Install the seven fuel injection pump housing mounting bolts. Make sure the ground body bolts are installed in their original locations.

4. Install the governor-to-right aftercooler housing mounting bracket. Install the two governor-to-left cylinder head bracket mounting bolts. Install the three fuel injection pump housing-to-right cylinder head mounting brackets.

5. Connect wiring to fuel shutoff solenoid (if so equipped). Install the fuel ratio control sensing line.

6. Install the governor control channel assembly. Connect the governor control linkage to the governor.

7. Install the two oil drain elbow-to-cylinder block mounting bolts. Install the fuel inlet line and the fuel return line. Connect drain line to fuel filter housing. Position the aftercooler vent line and tighten fittings.

8. Install the variable timing unit drive gear, retainer, mounting bolts and lock. Do not tighten the mounting bolts.

9. Time the fuel injection pump camshaft to engine. See FUEL INJECTION PUMP CAMSHAFT TIMING in TESTING AND ADJUSTING.

10. Install the variable timing unit cover. Install the two turbocharger oil drain lines.

concluding step:

a) install fuel injection lines

Disassemble Fuel Injection Pump Housing

preparatory steps:

a) remove fuel injection pump housing governor and fuel filter housing as a unit

b) remove fuel transfer pump

c) remove governor

d) remove variable timing unit

e) remove fuel filter housing

1. Remove the timing pin assembly from its storage position. Install one of the pin retaining bolts upside down through one of the flange holes. Insert the pin assembly into timing hole and move rack back and forth slowly until the timing pin engages slot in rack. Depress timing pin until head of inverted bolt (1) touches housing.


NOTICE

Do not attempt to remove fuel injection pumps if rack is not positioned as outlined above.


2. Identify each of the fuel injection pumps by its location in the fuel injection pump housing. Remove the pump mounting bolts. Pull straight up on each pump to remove it from housing.

3. Disassemble the fuel injection pumps as follows: Using wrench (A), remove the retainer. Remove the valve and spring. Pull the plunger out of the body to remove plunger, washer and spring.


NOTICE

While disassembling fuel injection pumps, exercise considerable care to prevent damage to plunger surfaces. The body and plunger assemblies are matched and are not interchangeable with other bodies or plunger assemblies.


4. Remove the cover (2). Remove the rack position indicator lever. Remove the timing pin assembly.

5. Remove the rack (3) from fuel injection pump housing.

6. Remove the lifter assemblies (4). Keep the lifter assemblies identified and together with their respective pumps.


NOTICE

Do not attempt to remove or replace the spacers in lifter assemblies. An improperly staked spacer can cause engine failure.


7. Remove the fuel transfer pump drive gear (5), retainer, lock and mounting bolts.

8. Remove the housing bottom cover (6) and mounting bolts. Pull the fuel injection pump camshaft (7) out of the housing.

9. Using tool group (B), remove the camshaft bearings.

10. Remove the rack bearings using tool setup (C).

11. Remove the variable timing unit bearing from the fuel injection pump housing.

Assemble Fuel Injection Pump Housing

1. Using tool setup (A), install the variable timing unit bearing with the hole in bearing aligned with hole in fuel injection pump housing.

2. Install the two rack bearings using tool setup (B). The front rack bearing should be recessed .38 in. (9,65 mm) from the front face of housing. The rack rear bearing should be installed 6.372 in. (161,8 mm) from the variable timing unit end of fuel injection pump housing.

3. Install the four camshaft bearings using tool group (C).

4. Lubricate the camshaft with clean engine oil and install in housing. Install the fuel transfer pump drive gear, retainer, lock and mounting bolts. Install the fuel injection pump housing bottom cover and mounting bolts.

5. Install the lifter assemblies (1) in their respective positions in housing. Lubricate the rack generously with clean fuel oil and install in housing.

NOTE: If new lifter assemblies and pumps are to be installed, it will be necessary to set the fuel pump timing dimension. See FUEL PUMP TIMING DIMENSION SETTING (OFF ENGINE) in TESTING AND ADJUSTING.

6. Install one of the timing pin retaining bolts, upside down, through one of the flange holes in timing pin assembly. Insert the pin assembly into the timing hole in housing. Move the rack back and forth slowly until the timing pin engages slot in rack. Depress the timing pin until head of inverted bolt touches housing.


NOTICE

Do not attempt to install fuel injection pumps if rack is not positioned as outlined above.


7. Install rack position indicator lever (2) and cover.

8. Assemble the fuel injection pumps as follows: Lubricate all parts generously with clean fuel oil. Install the spring, washer and plunger in the body. Install the valve, spring and bonnet in body. Using wrench (D), tighten bonnet to 145 ± 5 lb. ft. (20,05 ± 0,7 mkg).

9. Install the fuel injection pumps in their respective positions as follows. Rotate the camshaft until lifter assembly is down for the pump to be installed. Position the pump over the opening in housing. Sight down the pump and align the flat on gear with alignment pin in lifter assembly. Install the pump in housing. If the pump gear is properly aligned with alignment pin, the distance between pump body and fuel injection pump housing should be approximately 3/8 in. (10 mm) with the pump spring not compressed. Install the pump mounting bolts.

10. Remove the timing pin assembly from timing hole in fuel injection pump housing. Install the pin assembly in its storage position in housing.

concluding steps:

a) install variable timing unit

b) install governor

c) install fuel transfer pump

d) install fuel filter housing

e) install fuel injection pump housing, governor and fuel filter housing as a unit

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