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

Installation Procedure

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

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Illustration 1	g01572496
Typical example

Note: A new fuel injection pump is supplied, locked in the correct position. Do not unlock the fuel injection pump before installation.

1. If the fuel injection pump timing has been lost, it is possible to reset the fuel injection pump timing. Follow Step 1.a through Step 1.e in order to reset the fuel injection pump timing.

   1. 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.

   2. 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.

   3. 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.

   4. 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.

      The fuel injection pump is now locked.

   5. Remove Tooling (E) .

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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) 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 Center Position for No.1 Piston".

7. 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.

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".

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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) .

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.