MANIFOLD 1P2166 - Caterpillar

Removal Procedure
Table 1
Required Tools
Tool Part Number Part Descriptions Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
B 230-6284 Timing Pin (Camshaft) 1
C 230-6283 Timing Pin (Crankshaft) 1
D 1P-2320 Combination Puller 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.Start By:
Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install". Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
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.Dispose of all fluids according to local regulations and mandates.
Note: Care must be taken in order to ensure that the fuel injection pump timing is not lost during the removal of the fuel pump gear. Carefully follow the procedure in order to remove the fuel pump gear.
Use Tooling (A) in order to rotate the crankshaft so that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Finding Top Centre Position for No.1 Piston".
Illustration 1 g01459155
Typical example
Install Tooling (B) through Hole (X) in camshaft gear (1) into the front housing. Use Tooling (B) in order to lock the camshaft in the correct position.
Install Tooling (C) into Hole (Y) in the front housing. Use Tooling (C) in order to lock the crankshaft in the correct position. Note: Do not use excessive force to install Tooling (C). Do not use Tooling (C) to hold the crankshaft during repairs.
Illustration 2 g01459153
Typical example
Apply sufficient pressure to fuel injection pump gear (2) in a counterclockwise direction in order to remove the backlash. Lock fuel injection pump (3) in this position. In order to lock fuel injection pump (3), loosen locking screw (4) in the fuel injection pump. Slide spacer (5) into Position (YY). Tighten locking screw (4) against the shaft of the fuel injection pump to a torque of 9 N m (80 lb in).
Illustration 3 g01765133
Alignment of timing marks
Mark gear (1), gear (2) and gear (7) in order to show alignment. Refer to Illustration 3. Note: Identification will ensure that the gears can be installed in the original alignment.
Loosen nut (6) on fuel pump gear (2).
Install Tooling (D) through three holes in fuel pump gear (2). Tighten Tooling (D) until the fuel pump gear is released.
Remove Tooling (D) from fuel pump gear (2).
Remove nut (6) and the washer from fuel pump gear (2). Remove the fuel pump gear.