C6.6 Engines for Caterpillar Built Machines Fuel Injection Pump - Remove Caterpillar


Fuel Injection Pump - Remove
`
1.1. Removal Procedure

Removal Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
A(1)  9U-6198  Crankshaft Turning Tool 
A(2)  9U-7336  Housing 
5P-7305 Engine Turning Tool 
230-6284  Timing Pin (Camshaft) 
136-4632  Timing Pin (Crankshaft) 
268-1966 Adapter 
278-4138  Cap Kit 
(1) Install Tooling to the front pulley.
(2) Install Tooling into the aperture for the electric starting motor.

Start By:

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

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

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

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.



NOTICE

Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training.

Before begining 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 Systems Operation, Testing and Adjusting Manual, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.



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.


Note: Put identification marks on all hoses, on all hose assemblies, on wires and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.

  1. Turn the fuel supply to the OFF position.

  2. Turn the battery disconnect switch to the OFF position.

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

  4. If necessary, remove the fuel priming pump. Refer to Disassembly and Assembly, "Fuel Priming Pump - Remove".

  5. Use Tooling (A) in order 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 Centre Position for No.1 Piston".

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

  7. Remove the backlash from the fuel pump gear. Lock the fuel injection pump in the correct position and remove the fuel pump gear. Refer to Disassembly and Assembly, "Fuel Pump Gear - Remove and Install" for the correct procedure.


    Illustration 1g01563275
    Typical example


    Illustration 2g01563276
    Typical example

  8. Disconnect plastic tube assembly (2) from fuel injection pump (1).

  9. Disconnect harness assembly (6) from solenoid (3). Slide the locking tab into the unlocked position and disconnect harness assembly (6) from position sensor (7).

    Note: The harness assembly should be positioned in order to avoid an obstruction to the fuel injection pump.

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

  11. Disconnect plastic tube assembly (9) from fuel injection pump (1).

  12. Disconnect tube assembly (4) from fuel injection pump (1).

  13. Remove banjo bolt (13) and remove sealing washers (12). Remove tube assembly (11) .

    Note: In order to drain the fuel from the cylinder head, first disconnect tube assembly (11) at the fuel injection pump.

  14. Plug or cap all open ports and tube assemblies immediately with new plugs or caps.

    Note: Ensure that quick fit connections are clean before the tube assemblies are plugged.

  15. Remove fuel injection line (5). Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove". Use Tooling (D) in order to plug the open ports in the fuel injection pump and in the fuel manifold. Discard the fuel injection line.

  16. Remove tube assembly (8) for the engine oil supply to the fuel injection pump. Remove the banjo bolt and the sealing washers from the tube assembly.


    Illustration 3g01563333
    Typical example

  17. Remove bolts (15) and remove bolts (16). Remove support bracket (14).


    Illustration 4g01563853
    Typical example

  18. Remove bolts (18) and remove sealing washers (19).

    Note: The fuel injection pump should be supported by hand as the bolts are removed.

  19. Carefully remove fuel injection pump (1) from front housing (20). Ensure that bore (X) in the front housing is not damaged as the fuel injection pump is removed.

  20. Remove O-ring seal (17) from fuel injection pump (1).

Information System:

C6.6 Engines for Caterpillar Built Machines Fuel Injection Lines - Install
C6.6 Engines for Caterpillar Built Machines Fuel Injection Lines - Remove
C6.6 Engines for Caterpillar Built Machines Fuel Manifold (Rail) - Remove and Install
C6.6 Engines for Caterpillar Built Machines Fuel Transfer Pump - Install
C6.6 Engines for Caterpillar Built Machines Fuel Transfer Pump - Remove
C6.6 Engines for Caterpillar Built Machines Fuel Filter Base - Remove and Install - Secondary Fuel Filter
24M Motor Grader Power Train Transmission
24M Motor Grader Power Train Electronic Control System MID 027 - CID 0679 - FMI 06
3412E Engine for Caterpillar Built Machines Oil Pressure Is Low
259B3 Compact Track Loader, 247B3 and 257B3 Multi Terrain Loaders and 216B3, 226B3, 236B3, 242B3 and 252B3 Skid Steer Loaders Power Train Track Drive - Remove
C15 and C18 Generator Set Engines Radiator Core - Remove and Install - Jacket Water Heater
770 and 772 Off-Highway Truck/Tractors Steering Link - Remove and Install
C6.6 Engines for Caterpillar Built Machines Fuel Injection Pump - Install
C6.6 Engines for Caterpillar Built Machines Fuel Injection Pump Gear - Remove
C6.6 Engines for Caterpillar Built Machines Fuel Injection Pump Gear - Install
C6.6 Engines for Caterpillar Built Machines Turbocharger - Remove - Side Mounted Turbocharger
C6.6 Engines for Caterpillar Built Machines Turbocharger - Remove - Turbocharger Top Mounted
C6.6 Engines for Caterpillar Built Machines Turbocharger - Install - Side Mounted Turbocharger
C6.6 Engines for Caterpillar Built Machines Turbocharger - Install - Turbocharger Top Mounted
C6.6 Engines for Caterpillar Built Machines Wastegate Solenoid - Remove and Install
C6.6 Engines for Caterpillar Built Machines Exhaust Manifold - Remove and Install - Side Mounted Exhaust Manifold
C6.6 Engines for Caterpillar Built Machines Exhaust Manifold - Remove and Install - Top Mounted Exhaust Manifold
C6.6 Engines for Caterpillar Built Machines Exhaust Elbow - Remove and Install
C6.6 Engines for Caterpillar Built Machines Inlet Manifold - Remove and Install