COVER GP-VALVE MECHANISM 6I4035 - Caterpillar

Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Distilled Water -
De-ionized Water
Diesel Exhaust Fluid (DEF)
B 316-0704 Locking Pliers 2
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.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g03384472
Clamp off hoses (1) and (2) with Tooling (B).
Illustration 2 g03382731Note: Refer to Special Instruction, REHS8231, "Removal Procedures for Diesel Exhaust Fluid (DEF) Connectors" for the correct removal procedure of hose assemblies (3).
Disconnect harness assemblies (6). Remove clips (5) and (7).
Remove hose assemblies (3) and hoses (4).
Illustration 3 g03382869
Remove cable straps (8) and position the harness assembly out of the way.
Remove bolts (10) , cap (9), bolts (12), and manifold assembly (11).
Illustration 4 g03382907
Remove O-ring seals (13) from cap (9).
Illustration 5 g03382878
Remove cable straps (15) and disconnect harness assemblies (14), (16), and (17). Position harness assembly (18) out of the way.
Illustration 6 g03382883
Remove bolts (19), (20), (21), and bracket assembly (22).
Illustration 7 g03382905
Remove bolts (23) and diesel exhaust fluid pump (24).
Illustration 8 g06039312Note: Place identification marks on DEF pump coolant connectors (25) and DEF pump connectors (26) for installation purposes. DEF pump coolant connectors (25) and DEF pump connectors (26) are not interchangeable.
Remove DEF pump coolant connectors (25) and DEF pump connectors (26) from diesel exhaust fluid pump (24).Installation Procedure
Install diesel exhaust fluid pump (24) in reverse order of removal.
Tighten DEF pump connectors (26) to a torque of 4.5 0.5 N m (40 4 lb in).
Tighten DEF pump coolant connectors (25) to a torque of 5.5 0.5 N m (48 4 lb in).
Tighten bolts (23) to a torque of 19 2 N m (168 18 lb in).
Tighten bolts (19), (20), and (21) to a torque of 4 0.7 N m (35 6 lb in).
Tighten the bolt for clips (5) to a torque of 4 0.7 N m (35 6 lb in).
Apply Tooling (A) to the O-ring seals inside hose assemblies (3).