818116A 2 Force PISTON .030 OVERSIZE (NOT SHOWN)

Table 1
Required Tools
Tool Part Number Part Name Qty
A 9U-6198 Crankshaft Turning Tool 1
B 230-6284 Timing Pin (Camshaft) 1
C 230-6283 Timing Pin (Crankshaft) 1
D 150-3992 Timing Pin (Fuel Injection Pump) 1
E 1P-0510 Driver Group 1 Start By:
Remove the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley - Remove and Install".
Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".
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.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.Dispose of all fluids according to local regulations and mandates.
Use Tooling (A) to ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston". Note: Install Tooling (B) through the camshaft gear. Install Tooling (C) into the crankshaft web.
Illustration 1 g00944616
Fuel Injection Pump Gear
Insert Tooling (D) in the hole of fuel injection pump gear (2), through the slot in the hub and into the timing hole of the Fuel Injection Pump (X). If Tooling (D) can be fully inserted, the fuel injection timing is correct. There should be no resistance when Tooling (D) is inserted. Note: Do not remove hub nut (1) from the shaft of the fuel injection pump. The hub of the fuel injection pump is installed in the correct position from the factory in order to ensure proper timing. If hub nut (1) is removed and the hub is removed, the hub will need to be accurately installed on the shaft of the fuel injection pump by the use of special equipment. Refer to your Caterpillar Dealer for more information.
Illustration 2 g00995133
Loosen bolt (4). Remove spacer (5) in order to allow bolt (4) to tighten against the shaft of fuel injection pump (6). Rotate the fuel injection pump gear in a counterclockwise direction in order to remove the backlash. Tighten bolt (4) to a torque of 31 N m (23 lb ft). Note: Bolt (4) must be tightened in order to prevent the shaft of the fuel injection pump from rotating.
Illustration 3 g00995931
Remove Tooling (D) from the body of the fuel injection pump.
Remove bolts (3) and the washers from the hub of the fuel injection pump. Remove fuel injection pump gear (2).
Remove bolts (9) and retaining plate (8).
Illustration 4 g00995934
Remove idler gear (7) and idler gear hub (11).
Use Tooling (E) and remove bushings (10) from each side of the idler gear. Installation Procedure
Table 2
Required Tools
Tool Part Number Part Name Qty
A 9U-6198 Crankshaft Turning Tool 1
B 230-6284 Timing Pin (Camshaft) 1
C 230-6283 Timing Pin (Crankshaft) 1
D 150-3992 Timing Pin (Fuel Injection Pump) 1
E 1P-0510 Driver Group 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Use Tooling (A) to ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".