REHS772804

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Special Instruction
Replacement Procedure for Fuel Injection Pump on Certain CT11 and CT13 Engines in
CT660 Vocational Trucks{7000}
Media Number -REHS7728-04
Publication Date -05/06/2013
Date Updated -05/06/2013
i05354429
Replacement Procedure for Fuel Injection Pump on Certain
CT11 and CT13 Engines in CT660 Vocational Trucks{7000}
SMCS - 7000
On Highway Truck:
CT660 (S/N: TRK100-623; TKL100-168)
Introduction
Table 1
Required Parts
Part
Part Number
Description
Qty
1
358-0258
Washer
1
2
358-0265
Locknut
1
3
358-1080
Special Bolt
1
4
421-3155
Fuel Injection Pump Kit
1
5
N/A
high-pressure fuel line assembly
1
6
N/A
high-pressure fuel line assembly
1
The 380-9329 Fuel Injection Pump Gp on certain CT11 and CT13 engines used in CT660 may need
to be replaced.
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Fuel Injection Pump Removal
Before service work is begun, park the machine on a hard level surface.
Block the wheels of the machine so unexpected movement will not
occur. Unexpected movement of the machine can cause personal injury
or death.
NOTICE
Remove the ground cable from the negative terminal of the battery box
before disconnecting any electrical components. Always connect the
ground cable last.
NOTICE
Always wear safe eye protection when performing vehicle
maintenance. Failure to do so may result in serious eye injury.
1. Turn steering wheel to the left.
2. Install wheel chocks.
3. Remove battery box cover and disconnect negative cables from battery.
4. Open hood.
5. Remove left front fender assembly and bracket.
6. Remove air filter housing and tube. Install the 373-4730 Caps .
7. Remove charge air pipe and install protective caps.
NOTICE
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To avoid damaging the steering shaft, use a pry bar to detach the
steering shaft from the steering gear.
8. Detach steering shaft from steering gear and position away from injection pump. Discard bolt,
flat washer, and lock nut.
9. Remove the oil dipstick brace and oil filler pipe.
Illustration 1
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10. Unlock and disconnect all electrical connectors from Electronic Control Module (ECM).
11. Remove eight mounting bolts and remove ECM from support.
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Illustration 2
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(1) ECM support bracket
(2 ) Mounting bolts with attachment insulators
(3) Cold Start Solenoid (CSS)
(4) Cold Start Relay
12. Remove two attachment bolts and cold start solenoid (CSS) (3) from ECM support bracket (1)
and position the ECM out of the way.
13. Remove ECM support bracket (1). Retain mounting insulators.
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Illustration 3
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(5) Power steering pump
(6) Pressure tube fitting nuts
Note: Place a drain pan under the power steering pump to catch any fluid.
14. Disconnect power steering pressure tubes and drain power steering.
Note: To assist with fuel injection pump removal, the power steering pressure tubes, with two
insulated support brackets, must be laid aside as an assembly. Secure the two support brackets
with tie straps before loosening attachment fasteners, or reassembly can be difficult.
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Illustration 4
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15. Install tie straps on both upper and lower support brackets to prevent opening of brackets when
removed in Step 16
Illustration 5
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(7) Support Bracket Nut
(8) Support Bracket
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16. Remove upper and lower support bracket nuts (7). Slide support brackets (8) off studs and
move pressure tube assembly aside.
Illustration 6
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(9) Spring clamp
(10) High-pressure power steering line
17. Remove spring clamp (9) and disconnect rubber power steering hose at return tube. Disconnect
high-pressure power steering line (10) and position the line out of the way.
18. Release auto-tensioner and remove drive belt.
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Illustration 7
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(11) Fuel Injection Pump
(12) Bracket to pump bolt
(13) High-pressure pump support bracket
(14) Bracket to crankcase bolts
19. Remove two bracket-to-pump bolts (12) and loosen but do not remove two bracket-tocrankcase bolts (14) at fuel injection pump support bracket (13) .
20. Label and disconnect alternator wiring, and remove alternator assembly.
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Illustration 8
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21. Disconnect 21-way harness connector at mounting bracket.
22. Disconnect harness (15) from Fuel Pressure Control Valve (FOCV) on the fuel injection pump.
Illustration 9
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Do not open the high pressure fuel system without allowing the fuel
system to purge. After the engine has shut down, allow the fuel system
to purge for ten minutes. This operating fuel system contains high
pressure. Exposure to high pressure fuel can result in personal injury.
NOTICE
Whenever any fuel line (tubing) in the HP fuel system is removed the
fuel line must be replaced with new.
NOTICE
To prevent engine damage, install 373-4730 Disposable Air and Fuel
Caps immediately after each fuel line is removed.
23. Remove the fuel injection pump to rail tube assemblies (16). Cap open fuel rail connections
with clean protective cap.
Illustration 10
g03220180
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Note: Label four low-pressure fuel lines (17) on the fuel injection pump before removing the
lines for proper reinstallation.
24. Disconnect four low-pressure fuel lines (17) from side of the fuel injection pump.
Illustration 11
g03220197
25. Remove four mounting bolts and remove fuel injection pump and drive housing assembly from
crankcase.
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Illustration 12
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Illustration 13
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NOTICE
To prevent tool damage, make sure that the pins on holding plate align
between the teeth on the pump gear when installing the drive housing
on the holding plate.
26. Secure the holding plate in a vise.
Note: A dowel pin (19) and sleeve (20) are used to ensure correct placement of drive housing
on the engine block. DO NOT bolt holding plate to the drive housing with the dowel pin and
sleeve in place.
27. Install fuel injection pump drive housing (22) on the holding plate using four mounting bolts
removed in previous step. Torque four mounting bolts to 47 N·m (35 lb ft). Pump gear will be
locked in place by the holding plate.
28. Remove four attachment bolts (23) and remove fuel injection pump pulley housing (21) with
pulley still attached.
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Illustration 14
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29. Remove jam nut (24) and washer (25) securing pump gear to pump shaft.
Illustration 15
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30. Remove the four pump to drive housing bolts (26) and install two alignment studs (27) on
opposite sides of the fuel injection pump.
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Illustration 16
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31. Install forcing screw adapter (29) using two socket head cap screws (31), thread cap screws half
way into holes in pump gear.
32. Attach forcing screw adapter holder plate (28) to drive housing using four M10x40 bolts (30) .
33. Install forcing screw (32) by hand, into holding plate (28). Hand tighten until screw contacts
pump shaft and forcing screw adapter (29) is flush with forcing screw adapter holder plate
(28) .
34. Tighten two socket head cap screws (31) until the heads contact screw adapter plate (28) .
NOTICE
To avoid damage to components, do not use air tool to turn forcing
screw.
35. Turn forcing screw (32) clockwise until HP pump is removed from drive housing.
36. Remove HP pump from guide studs.
37. Remove socket head cap screws, forcing screw, forcing screw adapter, and adapter holding
plate from drive housing.
Fuel Injection Pump Install
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Illustration 17
(1) HP pump
(2) M10x40 Bolts
(3) Key
(4) Dowel Pin
(5) Drive Housing
(6) 25 X 44 X 4 Washer
(7) M24 Jam Nut
(8) Sleeve
(9) HP Fuel pump gear
(10) 100 X 3.349 O-ring
1. Install a new 100 x 3.349 O-ring on new pump mounting flange collar.
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Note: Install components and tighten bolts before sealant dries.
2. Clean joining faces of pump and drive housing. Apply RTV sealant to the drive housing joining
surface.
3. Slide new pump over guide studs while guiding pump shaft through center of pump gear.
4. Remove guide studs and install four M10x40 bolts. Torque bolts to 62 N·m (46 lb ft).
Illustration 18
g03222236
5. Install spacer (7) and jam nut (6). Torque nut to 285 N·m (210 lb ft).
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Illustration 19
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6. Clean joining faces of pump drive housing and pump pulley housing (11). Apply RTV sealant
to pump drive housing. Install four M10 X 40 bolts (12) and torque to 62 N·m (45 lb ft).
7. Remove drive housing and pump from holding plate.
Illustration 20
g03222756
8. Insure that dowel pins (13) and sleeves (14) are properly installed in pump drive housing and
crank case.
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9. Clean joining surfaces of the drive housing and the crank case. Apply RTV Sealant to the crank
case joining surface.
Illustration 21
g03222900
10. Position the fuel injection pump and the drive housing assembly on the crankcase using care to
align the pump drive gear with the idler gear. Install 1 M12 x 40 (17), 1 M12 x 90 (15), and 2
M12 x 130 (16) bolts and torque bolts to 105 N·m (77 lb ft).
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Illustration 22
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11. Install the pump support bracket.
a. Attach support bracket (20) to pump (18) with 2 M12 X 30 bolts (19), tighten finger tight.
b. Attach support bracket (20) to the crank case using 2 M14 X 30 bolts (21), tighten finger
tight.
c. Torque the M12 X 30 bolts (19) to 107 N·m (78 lb ft).
d. Torque the M14 X 30 bolts (21) to 172 N·m (126 lb ft).
Illustration 23
g03219282
12. Install four M16 X 1.5 quick connect fitting with 16.7 X 24 seal ring to the pump. Torque
fittings to 30 N·m (22 lb ft).
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Illustration 24
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13. Connect four low-pressure fuel lines to fittings.
Illustration 25
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14. Install new high-pressure fuel lines assembly (23) between the fuel injection pump and the fuel
rail. Hand tighten line fitting nuts. Start with the lines at the fuel rail first and then at the fuel
pump.
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15. Using a crow's-foot wrench, torque fittings at the fuel rail first and then at fuel pump. Torque
fittings to 23 N·m (17 lb ft). Tighten fittings an additional 60°.
16. Install alternator with four mounting bolts. Torque bolts to 61 N·m (45 lb ft) and connect
alternator wiring.
Illustration 26
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17. Using a hack-saw or other acceptable method, cut off harness support bracket from bottom of
ECM bracket.
Illustration 27
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18. Using grinder or other acceptable method, grind off any remaining stock close to profile of
ECM bracket. Remove any burrs or sharp edges.
19. Inspect harness and repair harness if evidence of rubbing through to copper is observed.
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Illustration 28
g03223117
20. Position ECM support bracket (25) on engine and reinstall six bracket insulators and three M8 x
40 bolts (26). Torque bolts to 13 N·m (120 lb in).
21. Install cold start solenoid (27) and cold start relay (28) on ECM support bracket. Torque 2 M6
X 20 bolts to6 N·m (53 lb in).
Illustration 29
g03223126
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22. Install two tie straps around the main vertical molded harness that runs near the ECM support
bracket. Install and tighten tie straps in an "X" configuration. The procedure will pull the
molded harness tightly against the ECM support bracket and away from the HP fuel tube
assemblies.
Illustration 30
g03223438
23. Position the ECM on the ECM support and install eight M6 x 30 bolts finger tight. Torque bolts
in sequence shown to 10 N·m (89 lb in).
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Illustration 31
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24. Tighten previously loose tie strap around the lower left ECM support bolt.
Illustration 32
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Illustration 33
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25. Align engine harness connectors (36) with mating terminals and push connectors straight in.
Push down on lock lever to draw in and secure connectors.
26. Install new tie straps to one lower (37) and two upper (35) tie strap locations.
Note: Insure that no harness is rubbing.
27. Secure harnesses to lower tie strap location to prevent harness chafing on top of the fuel
injection pump. Use more than one tie strap if needed to support harnesses.
Illustration 34
g03223616
28. Connect 21-way chassis harness connector (38) at connector bracket.
29. Position high-pressure and low-pressure tube as an assembly. Align HP power steering line at
union and tighten finger tight.
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Illustration 35
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30. Install M6 x 1.0 nut (40) onto extension clip stud (39) to secure rear support bracket at the oil
pan. Do not tighten at this time.
31. Install the upper support bracket.
32. If equipped, install front support bracket to stud on front engine support and tighten with M6 x
1.0 flange nut finger tight.
33. Torque both nuts to 13 N·m (115 lb in).
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Illustration 36
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34. Torque high-pressure tube fitting nut (41) to 62 N·m (45 lb ft).
35. Torque the low-pressure tubing nut (42) to 164 N·m (120 lb ft).
36. Install the dipstick brace and oil filler pipe and torque the three bolts to 24 N·m (18 lb ft).
Attach power steering supply tube and dipstick tube P-clamps and bolt.
Illustration 37
g03223656
(43) Old bolt
(44) New bolt
(45) Washer
(46) Locknut
Note: A new special bolt (44), washer (45), and lock nut (46) must be used when connecting
the steering shaft to the steering gear.
37. Connect steering shaft to power steering gear, observing alignment keyway. Install the 3581080 special bolt (44), 358-0258 washer (45), and 358-0265 locknut (46). Tighten bolt until the
head breaks off.
38. Install power steering return tube, supply line, and P-clamp. Torque to 62 N·m (45 lb ft).
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Illustration 38
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39. Release auto-tensioner and install drive belt.
40. Remove protective caps and install the charge air cooler outlet hose.
41. Remove protective caps and install air filter housing and tube.
42. Add 15W-40 motor oil to the power steering reservoir.
43. Connect negative battery cables and install battery box cover.
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Illustration 39
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(47) Fuel primer pump
(48) Fuel filter cover
(49) Fuel filter housing
(50) Water Drain
NOTICE
Do not crank the engine for more than 30 seconds. Allow the starter to
cool for two minutes before cranking again. Turbocharger damage can
result if the engine rpm is not kept low until the oil gauge display
verifies that the oil pressure is sufficient.
44. Prime fuel system.
a. Prime engine at hand primer pump.
b. Turn fuel primer pump knob (47) counterclockwise to unlock the pump stem.
c. Pump the fuel priming pump a minimum of 250 times (approximately 3 minutes).
Continue pumping even after higher pumping force is required. Make sure to raise and
lower the knob completely on each stroke.
d. After priming, depress the fuel primer pump knob fully and turn the fuel primer pump
knob clockwise until tight to secure the pump stem.
45. Connect negative battery cables and install battery box cover.
46. Start engine and check for fuel leaks. If engine does not start, prime again. Let engine run at
1,200 RPM for 2 minutes.
47. Verify that power steering reservoir is full.
a. Turn steering wheel to right until the wheel hits the axle stop.
b. Turn steering wheel to the left until the wheel hits the axle stop.
c. Refill power steering reservoir.
48. Install left front fender assembly and bracket.
49. Close and secure hood
50. Remove wheel chocks.
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Copyright 1993 - 2013 Caterpillar Inc.
Thu Jul 4 15:59:27 CDT 2013
All Rights Reserved.
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