HOUSING 4T1649 - Caterpillar

Removal Procedure
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
Illustration 1 g03641717
Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedures.
Loosen hose clamps (5) and hose clamps (4).
Remove tube assembly (6) from the water pump and the heat exchanger.
Loosen hose clamps (1) and hose clamps (3) (not shown).
Remove hose assembly (2) from the water temperature regulator and the heat exchanger.
Illustration 2 g03641760
Clean the area around flow control valve (8) and fuel injection pump (10). Ensure that the area is free from contamination before beginning disassembly.
Make temporary marks on flow control valve (8) and fuel injection pump (10) for installation purpose.
Remove allen heads bolts (7) from flow control valve (8).
Remove flow control valve (8) from fuel injection pump (10). Remove O-ring seal (11). Installation Procedure
Ensure that all component at free from wear and damage. If any part of the flow control valve is worn or damaged, the flow control valve must be replaced as an assembly. The flow control valve kit contains the guide pins in order to install the flow control valve assembly.
Illustration 3 g03641719
Illustration 4 g03641770
Flow control valve guide pins
Position a new O-ring seal (11) onto the fuel injection pump. Note: Ensure that the O-ring seal is correctly seated.
Check O-ring seals (12) is correctly positioned. Ensure that O-ring seals (12) is not damaged. Note: If the O-ring seal is damaged, a new flow control valve assembly must be installed.
Install guide pins into Position (X) on the fuel injection pump. Note: Note the guide pins are part of the flow control valve repair kit.
Lubricate O-ring seals (12) with clean fuel. Note: Ensure that the O-ring seals are not damaged or misaligned.
Position flow control valve (8) onto guide pins. Note: Ensure that the flow control valve is correctly orientated
Install flow control valve (8) to fuel injection pump (10).
Remove guide pins from fuel injection pump (10).
Install allen head bolts (11).
Tighten allen head bolts (11) equally until the flow control valve is seated correctly onto the fuel injection pump. Note: Ensure that the allen head bolts are tightened equally. Failure to ensure that the allen head bolts are tightened equally will result in damage to the fuel injection pump.
Tighten the allen head bolts to