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Home›Repair guides›Caterpillar›Fuel Injection Pump - Install - Delphi DP210

Caterpillar — Fuel Injection Pump - Install - Delphi DP210

Installation

From a Caterpillar service manual — check it applies to your exact model before use.

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Before you start

  • Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Procedure

  1. Use Tooling (C) to ensure that the No. 1 cylinder is at the top center compression stroke.
  2. Use Tooling (D) to lubricate O-ring seal (10). Install a new O-ring seal (10) onto the fuel injection pump.
  3. Install new washers to bolts (13).
  4. Align the holes in the fuel injection pump with the holes in the front housing. Install the pump.
  5. Install bolts (13). Tighten bolts (13) to a torque of 22 N·m (16 lb ft).
  6. Position support bracket (11) onto the cylinder block. Install bolt (15) finger tight.
  7. Install bolt (12) and nut (14) finger tight.
  8. Tighten bolt (12) and nut (14) to a torque of 22 N·m (16 lb ft). Tighten bolt (15) to a torque of 44 N·m (32 lb ft).
  9. Position fuel injection pump gear (9) on the shaft. Install washer and nut (8). Rotate gear counterclockwise to remove backlash. Tighten nut (8) to 24 N·m (17 lb ft).
  10. Connect the harness assembly to timing advance solenoid (7).
  11. Connect harness assembly (2). Connect fuel line (3).
  12. Connect fuel return line (1). Connect tube assembly (4) to the fuel injection pump.
  13. Loosen bolt (5). Move spacer (6) to prevent bolt (5) from tightening against the pump shaft. Tighten bolt (5) to 12 N·m (106 lb in).
  14. Tighten nut (8) to a torque of 88 N·m (65 lb ft).
  15. Remove Tooling (A) and Tooling (B). Install front cover, crankshaft pulley, fuel injection lines, and air compressor if equipped.

Tools required

  • 230-6284 Timing Pin (Camshaft) Amazon
  • 230-6283 Timing Pin (Crankshaft) Amazon
  • 9U-6198 Crankshaft Turning Tool Amazon
  • 1U-6396 O-Ring Assembly Compound Amazon

Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.

Specs & values

  • Bolts (13): 22 N·m (16 lb ft)
  • Bolt (12) and nut (14): 22 N·m (16 lb ft)
  • Bolt (15): 44 N·m (32 lb ft)
  • Nut (8) initial: 24 N·m (17 lb ft)
  • Nut (8) final: 88 N·m (65 lb ft)
  • Bolt (5): 12 N·m (106 lb in)

Source: Caterpillar service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.

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