5030736 JOHNSON GASKET, Pressure valve cover

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 157-3719 Ratchet Wrench 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the No. 1 cylinder is at top dead center on the compression stroke. Refer to the Testing and Adjusting Manual, "Finding Top Center Position for No. 1 Piston".
Ensure that all the mating surfaces are clean and free from fluid.
Illustration 1 g00994376
Install a O-ring seal (8) on the fuel injection pump. Position the fuel injection pump on the front housing. Install new sealing washers onto the setscrews and install the three setscrews (11). Tighten the setscrews to a torque of 22 N m (16.2 lb ft).
If necessary, install the setscrew and bracket (12) on the cylinder block. Tighten the setscrew by hand.
Install the nut and setscrew (13). Tighten the setscrew by hand. Note: The fasteners (12) and (13) must be secured after the front cover is installed.
Connect the tube assembly (9) to the fuel injection pump. Connect the tube assembly (10) to the fuel injection pump.
Connect the harness assembly (7) to the fuel injection pump. Push the locking mechanism in order to secure the harness assembly.
Use the 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".
Illustration 2 g00994453
Insert the Tooling (D) through the slot in the hub and into the timing hole of the Fuel Injection Pump. If the Tooling (D) can be fully inserted, the fuel injection timing is correct. There should be no resistance when the Tooling (D) is inserted. Note: The Tooling (B), the Tooling (C), and the Tooling (D) must be installed before the fuel injection pump gear (2) is installed on the hub of the fuel injection pump.Note: Some Bosch VP30 fuel injection pumps do not have a locking screw. For more information on timing the fuel injection pump, refer to Systems Operation, Testing and Adjusting, "Fuel Injection Timing - Check".Note: Do not remove the 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 the 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 3 g00994481
Fuel Injection Pump Gear
Position the slot in the fuel injection pump gear (2) over the Tooling (D). Install the four setscrews (3) and washers. Do not tighten the setscrews at this time.
Rotate the fuel injection pump gear counterclockwise in order to remove the backlash between the idler gear and the fuel injection pump gear. Tighten the four setscrews (3) to a torque of 22 N m (16.2 lb ft).
Remove the Tooling (D) from the fuel injection pump. Remove the Tooling (B) from the camshaft gear. Remove the Tooling (C) from the crankshaft web.
Illustration 4 g00995133
Loosen the setscrew (4). Install the spacer (5) in order to prevent the setscrew (4) from tightening against the shaft of the fuel injection pump (6). Tighten the setscrew (4) to a torque of 12 N m (9 lb ft). End By:
Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".
Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".
Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley - Remove and Install".
Refer to illustration 1. Tighten the setscrew (12) to a torque of 44 N m (32.5 lb ft). Tighten the setscrew and the nut (13) to a torque of 22 N m (16.2 lb ft).
Install the air compressor, if equipped. Refer to Disassembly and Assembly, "Air Compressor - Remove and Install".