PUMP GP-FUEL INJECTION 1086634 - Caterpillar

All Caterpillar 3208 Engines This instruction should be included in the 3208 Engine Tune-Up Kit. See the Engine Service Guide, Form No. SEBF2561.The tune-up will need the following special tools: 1 Steam clean the engine. Obtain an SOS sample; be sure the oil is hot and well mixed before you take the sample. Disconnect the batteries.2 Disconnect the hose(s) from the positive crankcase ventilator valve(s). Remove the right valve cover. 3 Remove four bolts (1) that hold the rocker shaft assembly in position. Remove the rocker shaft and bracket. Be sure to install the rocker shaft and bracket assembly on the same side from which they were removed.4 Clean the area around each fuel line connection thoroughly. Disconnect fuel injection line (3) from the adapter. Disconnect fuel injection nozzle (4) from each adapter. Remove clamp (5) and the spacers that hold the fuel injection nozzles in position.
Never use force, such as a prybar, to remove the fuel injection nozzles. If necessary, use 6V4061 Puller Group to remove the nozzles more easily.
5 Remove adapters (6) from the cylinder head. Remove the fuel injection nozzles. Put 2F2990 Plugs and 5F2807 Caps on fuel openings and protect the nozzle tips from damage and dirt entry.6 Remove the left valve cover and the left rocker shaft assembly. Remove the adapters and fuel injection nozzles from the left cylinder head assembly.7 Make sure new seals are on the fuel line adapters and fuel injection nozzles. Use a twisting motion to install the nozzle into its correct position. Never put lubrication on the nozzle or bore in the cylinder head.8 Install the adapters in the cylinder head. Connect the nozzle and fuel injection lines to the adapter. Use 5P0144 Socket to tighten the nuts to a torque of 40 7 N m (30 5 lb.ft.). Install the spacer and clamp that hold each nozzle to the cylinder head.9 Position the rocker shafts on the engine. Install the rocker shaft bolts and tighten them to 24 7 N m (18 5 lb.ft.).10 No. 1 piston at top center (TC) on the compression stroke is the starting point for adjusting valve clearances. Remove the plug from timing hole (8) in the front cover. Put bolt (7) in timing hole (8). The bolt from hole (9) can be used. Turn the crankshaft counterclockwise (as seen from the rear of the engine) until bolt (7) will go into the hole in the drive gear for the camshaft.11 The two valves at the right front of the engine are the intake and exhaust valves for No. 1 cylinder, and must now be closed; the timing pointer will be in alignment with the TC on the damper assembly. The No. 1 piston is now at TC on the compression stroke. 12 Make adjustment to the valves for No. 1 and No. 2 cylinders. To adjust, loosen locknut (11) and turn adjustment screw (10) until feeler gauge (12) will go between the end of the valve stem