PLUG 1797267 - Caterpillar

Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 364-9107 Fuel Injection Pump Timing Pin 1
B 230-6284 Timing Pin (Camshaft) 1
C 136-4632 Timing Pin (Crankshaft) 1
268-1966 Adapter 1
D 298-5564 T40 Torx Socket 1 Start By:
Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure.
Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure. Note: Care must be taken in order to ensure that the fuel injection pump timing is not lost during the removal of the idler gear. Carefully follow the procedure in order to remove the fuel pump gear.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01994555
Illustration 2 g01994553
Rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.
Remove plug (2) from the cylinder block and remove O-ring seal (1) from the plug.
Ensure that Tooling (C) is installed in Hole (Y) in the cylinder block. Use Tooling (C) in order to lock the crankshaft in the correct position.
Ensure that Tooling (B) is installed into Hole (X) in camshaft gear (3). Use Tooling (B) in order to lock the camshaft in the correct position. Note: Ensure that the gears are marked in order to show alignment. Refer to Illustration 2.
Use Tooling (A) in order to lock the fuel injection pump gear in the correct position. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove" for the correct procedure.
Illustration 3 g01994556
Use Tooling (D) in order to loosen threaded inserts (5) on all rocker arms (6). Unscrew threaded inserts (5) on all rocker arms (6) until all valves are fully closed. Note: Failure to ensure that ALL threaded inserts are fully unscrewed can result in contact between the valves and pistons.
Illustration 4 g01994576
Illustration 5 g01994557
Mark plate (8) in order to show orientation. Note: Identification will ensure that the plate can be installed in the original orientation.
Remove bolts (7).
Remove plate (8).
Remove the assembly of idler gear (4).
Remove hub (9) from the recess in the front housing.