ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 005-084   Fuel Pump Distributor Inlet Fitting

WARNING  When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

CAUTION  Fault Codes can occur if steam sprays directly on the electrical connections on top of the accumulated block.

• Thoroughly steam-clean the distributor inlet fitting and fuel pump area.
• Dry with compressed air.
• Remove the fuel pump distributor and injection control valve module assembly.
  Refer to Procedure 005-086 (Fuel Pump Distributor and Injection Control Valve Module) in Section 5.

NOTE: Injection control valve does not need to be removed from the distributor module.

Remove the distributor inlet fitting and the seal disc.

NOTE: A tool like the one shown in this procedure can be made from a 1/8-inch or 3/16-inch Allen wrench. Use it to remove the seal disc.

Two types of inlet fittings and sealing washers may be in use. A flat washer will be installed in most new pumps and a piloted washer (2) will be installed in some ReCon® pumps.

Different removal techniques are necessary based on the type of sealing washer being removed.

Removal of “piloted seal washer”

Use a plastic hammer to tap a spiral easy out into the center hole of the sealing washer. Turn the easy out
counterclockwise to dislodge the washer.

Removal of a “flat washer”

The flat sealing washer is swaged into the inlet fitting bore during installation. A special tool can be made to aid in its removal by grinding the short leg of a 1/8-inch or 3/16-inch Allen wrench so that the wrench is no longer than 13-mm [1/2-in] long (measured from the outside of the long leg). This tool acts as a mini heel bar to pry out the sealing washer without damaging the back of the hole.

Pry out the old sealing washer with the modified Allen wrench.

Substantial of force is required to remove the sealing washer.

CAUTION  Any debris left in this fitting during assembly will run through the fuel pump. Damage to the fuel pump can occur.

Use QD contact cleaner, Part Number 3824510, to clean the inlet fitting bore from the bottom of the bore outward.

CAUTION  Any dirt trapped in this fitting during assembly will run through the fuel pump. Damage to the fuel pump can occur.

Install the sealing washer into the distributor. Make sure the sealing washer is seated correctly in the distributor bore before installing the inlet fitting.

Install the new inlet fitting.

• Install the fuel pump distributor and injection control valve module assembly.
  Refer to Procedure 005-086 (Fuel Pump Distributor and Injection Control Valve Module) in Section 5.
• Start the engine and check for fuel leaks at the rate shape tube connections.
• Road-test the vehicle. Check again for fuel leaks or active fault codes.