CYLINDER ASSEM. 4H5469 - Caterpillar

START BY:a. remove fuel injection linesb. remove fuel filter and base Put caps or plugs on all fuel system openings to keep dirt or foreign material out of the fuel system. 1. Remove oil inlet line (2) and oil drain line (1) from the turbocharger. Install plugs in the openings in the turbocharger and cylinder block. 2. Remove bolt (5) that holds fuel line (3) to the cover.3. Remove fuel lines (3) and (4). 4. Remove bolt (7) and plug (6) from the timing gear cover. 5. Loosen bolt (8) which holds the fuel pump drive gear to the fuel injection pump camshaft a maximum of one turn. 6. Remove three bolts (9) that hold the fuel system to the oil manifold for the engine oil cooler.7. Loosen three nuts (10) that hold the fuel system to the timing gear plate. Loosen the nuts until they are even with the end of the studs.
Tooling (A) must be installed in the position shown so the locks will not damage the water passage in the timing gear cover.
8. Loosen the drive gear from the fuel injection pump camshaft with tooling (A) as follows:a. Install tooling (A) in the position shown, and tighten the locks to hold the tooling in place.b. Turn the extension counterclockwise to loosen the bolt in the fuel injection pump camshaft. As the bolt is loosened, it will push against tooling (A), and push the fuel injection pump camshaft out of the drive gear.c. Remove tooling (A) from the timing gear cover. Remove the bolt and washer from the fuel injection pump camshaft.9. Remove three nuts (10). See illustration B85592X1, and remove the fuel system from the engine. The weight of the fuel system is 22 kg (49 lb.).Install Fuel Injection Pump Housing And Governor
1. Install the fuel injection pump housing and governor on tooling (A), or use a suitable vise to hold the unit.2. Remove three bolts (2), cover (1) and the gasket from the fuel injection pump housing. 3. Install the bolt and washer used to hold the drive gear to fuel injection pump camshaft (3).4. Install tool (B) in the hole of the fuel injection pump housing. Turn fuel injection pump camshaft (3) until timing pin (B) engages in the notch in the fuel injection pump camshaft. Tool (B) will hold the fuel injection pump camshaft in the correct position to set the fuel injection timing pin of the engine. 5. Be sure O-ring seals (4) and 95) are in position on the governor and the fuel injection pump housing.
Be extra careful not to damage the O-ring seals when the fuel injection pump housing and governor are installed on the engine.
6. Put fuel system (6) in position on the engine, and install the three nuts which hold it. 7. Check the condition of the threads on bolt (7) which holds the drive gear to the fuel injection pump camshaft. Also, check the threads in the fuel injection pump camshaft. Put clean engine oil on