Fuel Injection Pump - Install

Installation Procedure

1. Ensure that the No. 1 cylinder is at top dead center on the compression stroke.
Refer to the Testing and Adjusting Manual, "Finding Top Center Position for No.
1 Piston".

2. Ensure that all the mating surfaces are clean and free from fluid.

3. Install a O-ring seal (8) on the fuel injection pump. Position the fuel injection
pump on the front housing. Install new sealing washers onto the setscrews and
install the three setscrews (11). Tighten the setscrews to a torque of 22 N·m (16.2
lb ft).
4. If necessary, install the setscrew and bracket (12) on the cylinder block. Tighten
the setscrew by hand.

5. Install the nut and setscrew (13). Tighten the setscrew by hand.

Note: The fasteners (12) and (13) must be secured after the front cover is
installed.

6. Connect the tube assembly (9) to the fuel injection pump. Connect the tube
assembly (10) to the fuel injection pump.

7. Connect the harness assembly (7) to the fuel injection pump. Push the locking
mechanism in order to secure the harness assembly.

8. Use the Tooling (A) to ensure that the No. 1 cylinder is at the top center
compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position
for No. 1 Piston".

9. Insert the Tooling (D) through the slot in the hub and into the timing hole of the
Fuel Injection Pump. If the Tooling (D) can be fully inserted, the fuel injection
timing is correct. There should be no resistance when the Tooling (D) is inserted.

Note: The Tooling (B), the Tooling (C), and the Tooling (D) must be installed
before the fuel injection pump gear (2) is installed on the hub of the fuel injection
pump.

Note: Do not remove the hub nut (1) from the shaft of the fuel injection pump.
The hub of the fuel injection pump is installed in the correct position from the
factory in order to ensure proper timing. If the hub nut (1) is removed and the hub
is removed, the hub will need to be accurately installed on the shaft of the fuel
 injection pump by the use of special equipment. Refer to your Caterpillar Dealer
for more information.

10. Position the slot in the fuel injection pump gear (2) over the Tooling (D). Install
the four setscrews (3) and washers. Do not tighten the setscrews at this time.

11. Rotate the fuel injection pump gear counterclockwise in order to remove the
backlash between the idler gear and the fuel injection pump gear. Tighten the four
setscrews (3) to a torque of 22 N·m (16.2 lb ft).

12. Remove the Tooling (D) from the fuel injection pump. Remove the Tooling (B)
from the camshaft gear. Remove the Tooling (C) from the crankshaft web.
 13. Loosen the setscrew (4). Install the spacer (5) in order to prevent the setscrew (4)
from tightening against the shaft of the fuel injection pump (6). Tighten the
setscrew (4) to a torque of 12 N·m (9 lb ft).

End By:

a. Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel
Injection Lines - Remove and Install".
b. Install the front cover. Refer to Disassembly and Assembly, "Front Cover -
Remove and Install".
c. Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft
Pulley - Remove and Install".
d. Refer to illustration 1. Tighten the setscrew (12) to a torque of 44 N·m (32.5 lb ft).
Tighten the setscrew and the nut (13) to a torque of 22 N·m (16.2 lb ft).
e. Install the air compressor, if equipped. Refer to Disassembly and Assembly, "Air
Compressor - Remove and Install".