104700-9071 ZEXEL 9 460 614 002 BOSCH INJECTION-PUMP ASSEMBLY 9460614002 1047009071

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 614 002 9460614002

ZEXEL 104700-9071 1047009071

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Components :

0.	INJECTION-PUMP ASSEMBLY	104700-9071
1.	_
2.	FUEL INJECTION PUMP	104600-9071
3.	NUMBER PLATE	148643-1000
4.	_
5.	CAPSULE
6.	ADJUSTING DEVICE
7.	NOZZLE AND HOLDER ASSY
8.	Nozzle and Holder
9.	Open Pre:MPa(Kqf/cm2)
10.	NOZZLE-HOLDER
11.	NOZZLE

Scheme ###:

1/6.	[1]	146601-0700	PACKING RING
6.	[1]	146100-0120	SUPPLY PUMP
9.	[1]	148103-0400	COVER
10.	[2]	139104-0000	FLAT-HEAD SCREW
12.	[1]	148200-0520	DRIVE SHAFT
17.	[1]	146204-0000	PLAIN WASHER
20.	[1]	148210-0120	ROLLER SET
24.	[1]	146303-0000	BEARING PIN
25.	[1]	146304-0000	BEARING PIN
26.	[1]	146305-0000	CLAMPING BAND
27.	[1]	146205-0000	SLOTTED WASHER
29.	[1]	146220-2120	CAM PLATE
30.	[1]	146600-0800	O-RING
31.	[1]	146300-1900	PUMP PLUNGER
32.	[1]	146301-0000	SLIDING PIECE
33.	[1]	146603-1100	SHIM
34.	[1]	146306-1800	COMPRESSION SPRING
34B.	[1]	146306-2100	COMPRESSION SPRING
35/1.	[0]	146603-0700	SHIM D17.5&7.5T0.60
35/1.	[0]	146603-0800	SHIM D17.5&7.5T0.70
35/1.	[0]	146603-0900	SHIM D17.5&7.5T0.90
35/1.	[0]	146603-1000	SHIM D17.5&7.5T1.00
35/1.	[0]	146603-1100	SHIM D17.5&7.5T1.20
35/1.	[0]	146603-3600	SHIM D17.5&7.5T2.40
36.	[1]	146600-0800	O-RING
37.	[1]	479765-9521	TIMER PISTON SENSOR
38.	[2]	146622-1200	HEX-SOCKET-HEAD CAP SCREW
39.	[1]	146310-5600	COVER
40.	[2]	146622-1300	BLEEDER SCREW
43.	[1]	146230-0000	SHIM
44.	[1]	146230-0100	PLAIN WASHER
45.	[1]	146231-0001	SLOTTED WASHER
47.	[2]	146233-0000	SLOTTED WASHER
48/1.	[1]	146603-0000	SHIM D17.0&5.2T0.50
48/1.	[1]	146603-0100	SHIM D17.0&5.2T0.80
48/1.	[1]	146603-0200	SHIM D17.0&5.2T1.00
48/1.	[1]	146603-0300	SHIM D17.0&5.2T1.20
48/1.	[1]	146603-0400	SHIM D17.0&5.2T1.50
48/1.	[1]	146603-0500	SHIM D17.0&5.2T1.80
48/1.	[1]	146603-0600	SHIM D17.0&5.2T2.00
48/1.	[1]	146690-1400	SHIM D17&5.2T0.9
48/1.	[1]	146690-1500	SHIM D17&5.2T1.1
48/1.	[1]	146690-1600	SHIM D17&5.2T1.3
48/1.	[1]	146690-1700	SHIM D17&5.2T1.4
48/1.	[1]	146690-1800	SHIM D17&5.2T1.6
48/1.	[1]	146690-1900	SHIM D17&5.2T1.7
48/1.	[1]	146690-5800	SHIM D17&5.2T2.1
48/1.	[1]	146690-5900	SHIM D17&5.2T2.2
48/1.	[1]	146690-6000	SHIM D17&5.2T2.3
48/1.	[1]	146690-6100	SHIM D17&5.2T2.4
48/1.	[1]	146690-6200	SHIM D17&5.2T2.5
48/1.	[1]	146690-6300	SHIM D17&5.2T2.6
48/1.	[1]	146690-6400	SHIM D17&5.2T2.7
48/1.	[1]	146690-6500	SHIM D17&5.2T2.8
48/1.	[1]	146690-6600	SHIM D17&5.2T2.9
48/1.	[1]	146690-6700	SHIM D17&5.2T3.0
48/1.	[1]	146690-6800	SHIM D17&5.2T3.1
48/1.	[1]	146690-6900	SHIM D17&5.2T3.2
48/1.	[1]	146690-7000	SHIM D17&5.2T3.3
48/1.	[1]	146690-7100	SHIM D17&5.2T3.4
48/1.	[1]	146690-7200	SHIM D17&5.2T0.4
48/1.	[1]	146690-7300	SHIM D17&5.2T0.6
48/1.	[1]	146690-7400	SHIM D17&5.2T0.7
48/1.	[1]	146690-7500	SHIM D17&5.2T1.9
48/1.	[1]	146690-7800	SHIM D17&5.2T0.2
49.	[2]	146234-0500	GUIDE PIN
50.	[1]	146403-9620	HYDRAULIC HEAD
50.	[1]	146403-9620	HYDRAULIC HEAD
50.	[1]	146403-9620	HYDRAULIC HEAD
51.	[1]	146600-0000	O-RING
52/1.	[1]	146420-0000	SHIM D9.5&3.0T1.90
52/1.	[1]	146420-0100	SHIM D9.5&3.0T1.92
52/1.	[1]	146420-0200	SHIM D9.5&3.0T1.94
52/1.	[1]	146420-0300	SHIM D9.5&3.0T1.96
52/1.	[1]	146420-0400	SHIM D9.5&3.0T1.98
52/1.	[1]	146420-0500	SHIM D9.5&3.0T2.00
52/1.	[1]	146420-0600	SHIM D9.5&3.0T2.02
52/1.	[1]	146420-0700	SHIM D9.5&3.0T2.04
52/1.	[1]	146420-0800	SHIM D9.5&3.0T2.06
52/1.	[1]	146420-0900	SHIM D9.5&3.0T2.08
52/1.	[1]	146420-1000	SHIM D9.5&3.0T2.10
52/1.	[1]	146420-1100	SHIM D9.5&3.0T2.12
52/1.	[1]	146420-1200	SHIM D9.5&3.0T2.14
52/1.	[1]	146420-1300	SHIM D9.5&3.0T2.16
52/1.	[1]	146420-1400	SHIM D9.5&3.0T2.18
52/1.	[1]	146420-1500	SHIM D9.5&3.0T2.20
52/1.	[1]	146420-1600	SHIM D9.5&3.0T2.22
52/1.	[1]	146420-1700	SHIM D9.5&3.0T2.24
52/1.	[1]	146420-1800	SHIM D9.5&3.0T2.26
52/1.	[1]	146420-1900	SHIM D9.5&3.0T2.28
52/1.	[1]	146420-2000	SHIM D9.5&3.0T2.30
52/1.	[1]	146420-2100	SHIM D9.5&3.0T2.32
52/1.	[1]	146420-2200	SHIM D9.5&3.0T2.34
52/1.	[1]	146420-2300	SHIM D9.5&3.0T2.36
52/1.	[1]	146420-2400	SHIM D9.5&3.0T2.38
52/1.	[1]	146420-2500	SHIM D9.5&3.0T2.40
52/1.	[1]	146420-2600	SHIM D9.5&3.0T2.42
52/1.	[1]	146420-2700	SHIM D9.5&3.0T2.44
52/1.	[1]	146420-2800	SHIM D9.5&3.0T2.46
52/1.	[1]	146420-2900	SHIM D9.5&3.0T2.48
52/1.	[1]	146420-3000	SHIM D9.5&3.0T2.50
52/1.	[1]	146420-3100	SHIM D9.5&3.0T2.52
52/1.	[1]	146420-3200	SHIM D9.5&3.0T2.54
52/1.	[1]	146420-3300	SHIM D9.5&3.0T2.56
52/1.	[1]	146420-3400	SHIM D9.5&3.0T2.58
52/1.	[1]	146420-3500	SHIM D9.5&3.0T2.60
52/1.	[1]	146420-3600	SHIM D9.5&3.0T2.62
52/1.	[1]	146420-3700	SHIM D9.5&3.0T2.64
52/1.	[1]	146420-3800	SHIM D9.5&3.0T2.66
52/1.	[1]	146420-3900	SHIM D9.5&3.0T2.68
52/1.	[1]	146420-4000	SHIM D9.5&3.0T2.70
52/1.	[1]	146420-4100	SHIM D9.5&3.0T2.72
52/1.	[1]	146420-4200	SHIM D9.5&3.0T2.74
52/1.	[1]	146420-4300	SHIM D9.5&3.0T2.76
52/1.	[1]	146420-4400	SHIM D9.5&3.0T2.78
52/1.	[1]	146420-4500	SHIM D9.5&3.0T2.80
52/1.	[1]	146420-4600	SHIM D9.5&3.0T2.82
52/1.	[1]	146420-4700	SHIM D9.5&3.0T2.84
52/1.	[1]	146420-4800	SHIM D9.5&3.0T2.86
52/1.	[1]	146420-4900	SHIM D9.5&3.0T2.88
52/1.	[1]	146420-5000	SHIM D9.5&3.0T2.90
52/1.	[1]	146420-5100	SHIM D9.5&3.0T1.74
52/1.	[1]	146420-5200	SHIM D9.5&3.0T1.76
52/1.	[1]	146420-5300	SHIM D9.5&3.0T1.78
52/1.	[1]	146420-5400	SHIM D9.5&3.0T1.80
52/1.	[1]	146420-5500	SHIM D9.5&3.0T1.82
52/1.	[1]	146420-5600	SHIM D9.5&3.0T1.84
52/1.	[1]	146420-5700	SHIM D9.5&3.0T1.86
52/1.	[1]	146420-5800	SHIM D9.5&3.0T1.88
54.	[4]	146433-0100	GASKET
55.	[4]	146430-0320	DELIVERY-VALVE ASSEMBLY VE4
56.	[4]	146432-0000	COMPRESSION SPRING
58.	[4]	146440-3220	FITTING
60.	[3]	146622-1800	FLAT-HEAD SCREW
123.	[1]	146622-0900	FLAT-HEAD SCREW
130.	[1]	146421-1920	CAPSULE
130/2.	[1]	139508-0200	GASKET
130/3.	[1]	146422-0700	BLEEDER SCREW
130/4.	[1]	146600-0500	O-RING
133.	[1]	146600-0600	O-RING
134.	[1]	146600-0700	O-RING
135.	[1]	146110-3520	CONTROL VALVE
135/5.	[1]	146114-0000	SPRING WASHER
136.	[1]	148120-0320	OVER FLOW VALVE
137.	[3]	139512-0500	GASKET
138.	[1]	146669-5821	INLET UNION
158.	[1]	146663-5500	SPACER BUSHING
200.	[1]	146206-0100	COILED SPRING
205.	[1]	029470-4030	WOODRUFF KEY
230.	[1]	148613-6620	BRACKET
236.	[1]	146622-1400	HEX-SOCKET-HEAD CAP SCREW
237.	[1]	146622-1500	HEX-SOCKET-HEAD CAP SCREW
240.	[1]	146688-3720	PULLING ELECTROMAGNET
240/8.	[1]	146600-1700	O-RING
243.	[1]	146621-1000	UNION NUT
245.	[3]	139512-0500	GASKET
246.	[1]	146125-1000	EYE BOLT
247.	[1]	146669-6821	INLET UNION
248.	[1]	146663-5600	SPACER BUSHING
275.	[1]	148612-1600	BRACKET
276.	[2]	146622-1700	BLEEDER SCREW
278.	[2]	146663-5700	SPACER BUSHING
282.	[1]	146622-1900	BLEEDER SCREW
504/1.	[1]	146649-4500	RESISTER NO. 1 0.18K:OHM
504/1.	[1]	146649-4600	RESISTER NO. 2 0.30K:OHM
504/1.	[1]	146649-4700	RESISTER NO. 3 0.43K:OHM
504/1.	[1]	146649-4800	RESISTER NO. 4 0.62K:OHM
504/1.	[1]	146649-4900	RESISTER NO. 5 0.82K:OHM
504/1.	[1]	146649-5000	RESISTER NO. 6 1.10K:OHM
504/1.	[1]	146649-5100	RESISTER NO. 7 1.50K:OHM
504/1.	[1]	146649-5200	RESISTER NO. 8 2.00K:OHM
504/1.	[1]	146649-5300	RESISTER NO. 9 2.70K:OHM
504/1.	[1]	146649-5400	RESISTER NO.10 3.90K:OHM
504/1.	[1]	146649-5500	RESISTER NO.11 5.60K:OHM
504/1.	[1]	146649-5600	RESISTER NO.12 8.20K:OHM
504/1.	[1]	146649-5700	RESISTER NO.13 15.00K:OHM
505.	[1]	148530-3721	GOVERNOR;ELECTRIC
506.	[3]	146622-1000	FLAT-HEAD SCREW
515.	[1]	106144-1071	TIMING CONTROL VALVE
515/7.	[1]	161440-3800	O-RING
515/8.	[1]	161440-3700	O-RING
516.	[2]	146622-1600	HEX-SOCKET-HEAD CAP SCREW
530.	[2]	148650-0000	BINDER
531.	[1]	479765-8820	PULSE GENERATOR
531/6.	[1]	479773-6500	O-RING
800S.	[1]	148009-0620	PUMP HOUSING
800S/1/6.	[1]	146601-0700	PACKING RING
804S.	[1]	146232-0320	COMPRESSION SPRING
810S.	[1]	146600-4620	REPAIR SET
821S.	[1]	146210-5720	ROLLER SET
878S.	[1]	148600-1300	SEAL RING
906.	[1]	148643-1000	NAMEPLATE

Include in #2:

104700-9071 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 460 614 002 9460614002

ZEXEL 104700-9071 1047009071

Zexel num

Bosch num

Firm num

Name

104700-9071

9 460 614 002

INJECTION-PUMP ASSEMBLY
4D56TC 11CL INJECTION PUMP ASSY COVEC 4 COVEC

104700-9071
104700-9072

9 460 614 002

3310542600 HYUNDAI

INJECTION-PUMP ASSEMBLY
4D56TC * K 11CL INJECTION PUMP ASSY COVEC 4 COVEC

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105780-0060

Bosch type code NP-DN0SD1510

Nozzle holder 105780-2150

Opening pressure MPa 13 13 13.3

Opening pressure kgf/cm2 133 133 136

Injection pipe 157805-7320

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-450

Joint assembly 157641-4720

Tube assembly 157641-4020

Transfer pump pressure kPa 20 20 20

Transfer pump pressure kgf/cm2 0.2 0.2 0.2

Direction of rotation (viewed from drive side)
Right R

Governor adjustment

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Pump chamber pressure kPa 598.5 569 628

Pump chamber pressure kgf/cm2 6.1 5.8 6.4

Basic *

Governor adjustment_02

Pump speed r/min 100 100 100

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Pump chamber pressure kPa 294 294

Pump chamber pressure kgf/cm2 3 3

Governor adjustment_03

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Pump chamber pressure kPa 598.5 559 638

Pump chamber pressure kgf/cm2 6.1 5.7 6.5

Governor adjustment_04

Pump speed r/min 2000 2000 2000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Pump chamber pressure kPa 736 687 785

Pump chamber pressure kgf/cm2 7.5 7 8

Boost compensator adjustment

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 7.7 7.5 7.9

Basic *

Boost compensator adjustment_02

Pump speed r/min 100 100 100

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 1.8 0.3 3.3

Boost compensator adjustment_03

Pump speed r/min 350 350 350

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 5.2 3.1 7.3

Boost compensator adjustment_04

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 7.7 7.4 8

Boost compensator adjustment_05

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 70 70 70

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 4 1.9 6.1

Boost compensator adjustment_06

Pump speed r/min 2000 2000 2000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 9.75 9.3 10.2

Boost compensator adjustment_07

Pump speed r/min 2000 2000 2000

TCV duty (%) F TCV 60Hz % 0 0 0

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 0 0 0

Timer adjustment

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 0 0 0

U alpha soll V 2.7 2.7 2.7

Vtps V 0.51 0.382 0.638

Basic *

Timer adjustment_02

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 0 0 0

U alpha soll V 2.7 2.7 2.7

Vtps V 0.51 0.382 0.638

Timer adjustment_03

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Vtps V 1.925 1.702 2.148

Speed control lever angle

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Overflow quantity cm3/min 550 420 680

0000000901

Pump speed r/min 1250 1250 1250

U alpha soll + dU alpha soll V 2.86 2.86 2.86

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 72 71 73

Difference in delivery mm3/st. 3.5

Basic *

_02

Pump speed r/min 375 375 375

U alpha soll + dU alpha soll V 2 2 2

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 14.8 11.8 17.8

Difference in delivery mm3/st. 2.5

Basic *

Remarks
Confirmation of difference in delivery

_03

Pump speed r/min 2575 2575 2575

U alpha soll + dU alpha soll V 1.96 1.96 1.96

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 20.3 17.8 22.8

Difference in delivery mm3/st. 5.5

Basic *

Remarks
Confirmation of difference in delivery

_04

Pump speed r/min 100 100 100

U alpha soll + dU alpha soll V 3.31 3.31 3.31

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 67.9 57.9 77.9

_05

Pump speed r/min 375 375 375

U alpha soll + dU alpha soll V 2 2 2

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 14.8 11.8 17.8

_06

Pump speed r/min 500 500 500

U alpha soll + dU alpha soll V 2.74 2.74 2.74

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 51.2 48.7 53.7

_07

Pump speed r/min 750 750 750

U alpha soll + dU alpha soll V 2.83 2.83 2.83

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 63.1 60.6 65.6

_08

Pump speed r/min 1000 1000 1000

U alpha soll + dU alpha soll V 2.87 2.87 2.87

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 70.4 67.9 72.9

_09

Pump speed r/min 1250 1250 1250

U alpha soll + dU alpha soll V 2.86 2.86 2.86

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 72 71 73

_10

Pump speed r/min 1500 1500 1500

U alpha soll + dU alpha soll V 2.82 2.82 2.82

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 68.6 66.1 71.1

_11

Pump speed r/min 1750 1750 1750

U alpha soll + dU alpha soll V 2.8 2.8 2.8

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 65.5 63 68

_12

Pump speed r/min 1900 1900 1900

U alpha soll + dU alpha soll V 2.77 2.77 2.77

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 63.8 61.3 66.3

_13

Pump speed r/min 2575 2575 2575

U alpha soll + dU alpha soll V 1.96 1.96 1.96

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 20.3 17.8 22.8

_14

Pump speed r/min 2575 2575 2575

U alpha soll + dU alpha soll V 1 1 1

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 3

Stop lever angle

Pump speed r/min 1900 1900 1900

U alpha soll + dU alpha soll V 2.77 2.77 2.77

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity cm3/min 0 0 0

0000001101

Pump speed r/min 200 200 200

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Speed output
N=Measure the actual speed. r/min N+-8

0000001201

Pump speed r/min 1250 1250 1250

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.73 2.73 2.73

Temperature output
Measure T = actual output temperature degC T+-5

0000001301

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

Pre-stroke mm 0.1 0.08 0.12

Test data Ex:

Injection timing adjustment Comp. resistor/voltage

Compensation resistance/compensation voltage comparison A = Compensation resistor number B= Compensation resistance C = Compensation voltage delta U alpha soll
----------

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0000001601 HARNESS & CONNECTOR

TCV connector assembly specification (1)Ensure the GE cable is not twisted at section A. (2)Refer to the figure for the direction of connector clip B. (3)Route the TCV harness in the direction indicated by the arrows in the figure and install the connector C.
----------

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0000001701 HARNESS & CONNECTOR

F.C.V. harness assembly specifications (1)Route the F.C.V. harness under the G.E. cable at assembly. (2)Refer to connector and clip assembly standards for harness routing and the fixing of clips. A:Route the F.C.V. harness under the G.E. cable. B:Connector installation bracket
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a=(75deg)

0000001801 HARNESS & CONNECTOR

Connector and binder assembly specification (1)Assemble the connectors and clips in the order A, B, C, D, E, F, G and H. (2)Fix the GE cable and the FCV cable using the binder C. (3)Clip the GE cable, the TPS and the P/U harness using clip H. At this time, clip so that the TPS cover is not loose. (4)Where each connector and sensor harness comes out, ensure that the lead wires are not exposed or visible. A:Push type clip B:F.C.V. harness C:Clip (be careful of installation direction) D:G.E. Connector E:Q adjustment connector F:T.P.S. Connector G:P/U Connector H:Clip (be careful of installation direction) I:T.P.S. Cover
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Information:

Install Tooling (E). Tighten Tooling (E) to a torque of 9 1 N m (80 9 lb in).Note: The pump will not function while Tooling (E) is installed. Running the fuel injection pump with the tooling installed will result in pump damage and system contamination.
Illustration 6 g02025176
Disconnect harness assemblies (3).
Remove nut (5) and remove the clamp assembly. Discard the clamp assembly.
Loosen nuts (4) and (7). Remove the fuel line and discard the fuel line.
Disconnect hose assembly (6).
Illustration 7 g02029098
Disconnect tube assemblies (9).
Disconnect hose assemblies (10) and (11).
Remove bolts (8).
Illustration 8 g02029093
Disconnect tube assembly (12).
Illustration 9 g02025262
Remove bolts (13) and remove fuel pump (14).Installing the Fuel Injection Pump
Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.
Illustration 10 g02385860
Service replacement pump
Note: Service replacement pump is shipped pinned with warning tag (Z) installed under pinch bolt (E).
Illustration 11 g02025262
Position fuel pump (14) and install bolts (13).
Illustration 12 g02029093
Connect tube assembly (12).
Illustration 13 g02029098
Install bolts (8).
Connect tube assembly (9) and connect both hose assemblies (10) and (11).
Illustration 14 g02025176Note: During installation, make sure that the fuel line caps remain in position until the fuel line is positioned near the corresponding ports in order to prevent contamination. Ensure that the areas around the rail and fuel lines are thoroughly clean before continuing this procedure. If any parts are worn or damaged, use new parts for replacement. Cleanliness is an important factor. Ensure that no debris gets introduced into the fuel system during the installation procedure. If any parts are worn or damaged, use new parts for replacement.
Connect harness assemblies (3).
Install a new fuel line. Hand tighten nuts (4) and (7).
Position the clamp assembly and install nut (5). Hand tighten the nut. Failure to place the grommet correctly on the fuel line could result in a failed fuel line.Note: Ensure that the fuel lines are centered in the nuts prior to tightening. Do not use excessive force or bending in order to assemble the fuel lines.
Tighten nut (4) at the fuel rail to a torque of 27 3 N m (239 27 lb in).
Tighten nut (7) to a torque of 27 3 N m (239 27 lb in).
Tighten nut (5) to a torque of 12 3 N m (105 27 lb in).
Illustration 15 g02351995
Remove Tooling (E) and warning tag (Z).Note: The pump will not function while Tooling (E) is installed. Running the fuel injection pump with the tooling installed will result in pump damage and system contamination.
Illustration 16 g02351981
Install O-ring seal (2) and plug (1). Tighten the plug to a torque of 9 1 N m (80 9 lb in).
Illustration 17 g02112896
Remove all tooling. Reinstall plug (X) into the timing hole that is located in the flywheel housing.
Connect Caterpillar Electronic Technician (ET). Perform a “Fuel System Functional Test ”and a “Fuel System Verification Test”.