15.07.2023, 17:03 SIS 2.

2022/09/14 Fuel Injection Pump - Install (KENR6081-15)

SMCS - 1251 i09629252

Installation Procedure PIP

Table 1 -
202 1014
Required Tools

Tool Part Number Part Description

3
12: 07/1 261
/ 9 Qty
A(1) 9U-6198 0
KE 3:45+ 5
Crankshaft Turning Tool 1

A(2)
9U-7336
5P-7305
N
© 2 R60 05:00
Housing As
Engine Turning Tool
1
1
B 230-6284
023 81
Timing Pin (Camshaft) 1

C
136-4632
Cat
Timing Pin (Crankshaft) 1
268-1966 Adapter
erp 1

E 338-1054
Timing Tool
illa 1

F 1U-6396
(Fuel Injection Pump)
rI
O-Ring Assembly Compound -
nc.
(1) Install Tooling to the front pulley.
(2) Install Tooling into the aperture for the electric starting motor.

Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.

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.

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Illustration 1 g01572496
Typical example
Note: Ensure that the fuel injection pump is locked in the correct position before
installation.

1. It is possible to reset the fuel injection pump timing. Follow Step 1a through Step 1e to reset
the fuel injection pump timing.

a. Loosen locking screw (22) and slide spacer (21) to Position (AA). Tighten locking screw
(22) to a torque of 9 N·m (80 lb in). Placing the spacer into Position (AA) will prevent
the locking screw from tightening against the shaft of the fuel injection pump.
The fuel injection pump is now unlocked.

b. Position Tooling (E) onto the shaft of fuel injection pump (1). Align the lever of Tooling
(E) with Keyway (Y) and engage the lever into the keyway.
Note: The lever of Tooling (E) should be a close fit in the keyway. If the lever is a loose
fit in the keyway, It is not possible to reset the fuel injection pump timing.

c. Rotate the shaft of the fuel injection pump and engage the pin of Tooling (E) into Hole
(Z).
The fuel injection pump timing is now set in the correct position.

d. Loosen locking screw (22) and slide spacer (21) to Position (BB). Tighten locking screw
(22) to a torque of 9 N·m (80 lb in). The locking screw is now tightened against the shaft
of the fuel injection pump.

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The fuel injection pump is now locked.

e. Remove Tooling (E).

Illustration 2 g03172736
2. Inspect Bore (X) in front housing (20) for damage. If the bore is damaged, replace the front
housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove" and Disassembly
and Assembly, "Housing (Front) - Install".

3. Use Tooling (F) to lubricate a new O-ring seal (17). Install the O-ring seal onto fuel injection
pump (1).

4. Align fuel injection pump (1) with front housing (20). Carefully install the fuel injection pump
to the front housing.
Note: The fuel injection pump should be supported by hand until the bolts are installed.

5. Install bolts (18) and new sealing washers (19). Tighten the bolts to a torque of 25 N·m
(18 lb ft).
Note: One sealing washers should be installed to each bolt.

6. 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,
"Finding Top Center Position for No.1 Piston".

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7. Use Tooling (B) to lock the camshaft in the correct position. Use Tooling (C) to lock the
crankshaft in the correct position. Refer to Disassembly and Assembly, "Gear Group (Front)
- Remove" for the correct procedure.

8. Install the fuel injection pump gear to the fuel injection pump. Refer to Disassembly and
Assembly, "Fuel Injection Pump Gear - Install" and refer to Disassembly and Assembly,
"Gear Group (Front) - Install".
Note: Ensure that the fuel injection pump is unlocked after the installation of fuel injection
pump gear is completed.

9. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and
Install".

Illustration 3 g01563333
Typical example

10. Position support bracket (14) onto the fuel injection pump. Install bolts (15) finger tight.
Install bolts (16) finger tight.

11. Tighten bolts (15) to a torque of 22 N·m (16 lb ft). Tighten bolts (16) to a torque of 22 N·m
(16 lb ft).
If the support bracket is secured by an M10 bolt, tighten the bolt to a torque of 44 N·m
(32.5 lb ft).

Note: Ensure that the fuel injection pump is not stressed as the bolts are tightened.
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Illustration 4 g01563276
Typical example

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Illustration 5 g01563275
Typical example
12. Install the banjo bolt and new sealing washers to tube assembly (8). Install tube assembly
(8) for the oil feed to the fuel injection pump. Tighten the banjo bolt and the nut to a torque of
15 N·m (11 lb ft).

13. Install a new fuel injection line (5). Refer to Disassembly and Assembly, "Fuel Injection Lines
- Install".

14. Install new sealing washers (12) and banjo bolt (13) to tube assembly (11). Install tube
assembly (11). Tighten the banjo bolt to a torque of 21 N·m (15 lb ft).

15. Connect tube assembly (4) to fuel injection pump (1).

16. Connect plastic tube assembly (9) to fuel injection pump (1).

17. Connect plastic tube assembly (10) from fuel injection pump (1).

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18. Connect harness assembly (6) to solenoid (3). Connect harness assembly (6) to position
sensor (7). Slide the locking tab into the locked position.

19. Connect plastic tube assembly (2) to fuel injection pump (1).

20. If necessary, install the fuel priming pump. Refer to Disassembly and Assembly, "Fuel
Priming Pump - Remove and Install".

21. If necessary, install the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter
Base - Remove and Install".

22. Turn the battery disconnect switch to the ON position.

23. Turn the fuel supply to the ON position.

24. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel
System - Prime" for more information.

PIP-10149261
2023/07/15
12:02:12+05:00
i02786668
© 2023 Caterpillar Inc.

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