HARNESS AS-CAB 3612515 - Caterpillar

1. Remove the timing pin. Install a bolt up side down through one of the holes in the flange. Install the pin into timing hole, move the rack until the timing pin goes through the notch in rack. Push timing pin down until head of bolt (1) makes contact with housing. 2. Remove fuel injection pumps (3). Put identification on the pumps as to their location in the pump housing.
During disassembly and assembly of fuel injection pumps, do not cause damage to plunger surfaces. The bodies and plunger are special fitted, and the parts can not be changed with other bodies or plungers.
3. Put the pump in a vise as shown. Use tool (A) to loosen bonnet (4). 4. Remove bonnet (4), spring (6) and check valve (5) from the body. 5. Remove plunger (9), washer (8), spring (7) and O-ring seal (10) from the body.6. Remove cover (2). Remove the rack position indicator lever. 7. Remove timing pin (11). 8. Remove rack (12) from the fuel injection pump housing.
Do not remove or install the spacers in the lifters. A spacer that has been installed wrong can cause an engine failure.
9. Put identification on the lifters for installation purposes. Remove lifters (13) from the fuel injection pump housing. 10. Remove the locks and bolts from drive gear (14) for the fuel transfer pump. Remove gear (14). 11. Remove cover (15) and gasket from the bottom of the fuel injection pump housing. 12. Remove the locks, bolts, plate and shims that hold the variable timing unit in place. Remove variable timing unit (16) from the fuel injection pump housing. 13. Remove camshaft (17) from the fuel injection pump housing. 14. Remove the camshaft bearing from the fuel injection pump housing with tooling (B) as shown. 15. Remove bearings (18) for the rack from the fuel injection pump housing with tooling (C). 16. Remove bearing (19) for the variable timing unit from the fuel injection pump housing.Assemble Fuel Injection Pump Housing
1. Inspect the parts for damage and make replacements if needed. Make sure all the parts are clean. Put 5P0960 Multipurpose Type Grease on the O-ring seals. 2. Install the bearing for the variable timing unit with the oil hole in the bearing in alignment with the hole in the fuel injection pump housing with tooling (A). The inside diameter of the bearing after assembly must be 4.0054 .0019 in. (101.737 0.048 mm). 3. Install four camshaft bearings (1) in the fuel injection pump housing with tooling (C). Make sure the bearing junction (joint) is at an angle of 60 15° from the vertical centerline away from the rack. The inside diameter of the bearings after assembly must be 2.6258 .0019 in. (66.695 0.048 mm). 4. Install the bearing for the rack in the fuel injection pump housing with tooling (B). The rack front bearing must be .38 in. (9.7 mm) from the front surface of housing. The rack rear bearing must be installed