ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 005-016   Fuel Pump

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

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

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.

CAUTION  Clean all fittings before disassembly. Dirt or contaminants can damage the fuel system.

Before servicing any fuel system components, (such as fuel lines, fuel pump, injectors, etc.) which would expose the fuel system or internal engine component to potential contaminants prior to disassembly, clean the fittings, mounting hardware, and the area around the component to be removed. Dirt or contaminants can be introduced into the fuel system and engine if the surrounding areas are not cleaned, resulting in damage to the fuel system and engine. Refer to Procedure 000-009 in Section 0.

• Disconnect the batteries. Refer to Procedure 013-009 in Section 13.
• Remove the fuel supply lines from the fuel pump. Refer to Procedure 006-024.
• Remove the fuel drain line from the fuel pump. Refer to Procedure 006-013 in Section 6.
• Remove the fuel pump gear access cover.

WARNING  Normal engine operation creates highly pressurized fuel in the fuel line which will remain in the fuel line after engine shutdown. Never open the fuel system when the engine is operating. Before servicing the fuel system, always loosen the pump to rail fuel line at the rail to vent the pressure. Keep hands clear of the line when loosening. High pressure fuel spray can penetrate the skin, resulting in serious personal injury or death.

Before servicing the fuel system, loosen the pump to rail line at the rail to vent the pressure.

Keep hands clear of the line when loosening.

Tighten the fuel rail nut.

NOTE: A machined slot in this fitting directs the fuel spray towards the engine block.

Remove the fuel pump upper support bracket.

Locate top dead center for cylinder Number 1 by barring the engine until the line on the fuel pump gear aligns with the front cover mark for top dead center.

NOTE: Depending on the build year of the engine, the fuel pump support bracket can be mounted on the fuel pump head or the fuel pump actuator housing.

Remove the fuel pump gear nut and washer.

Use fuel pump gear puller, Part Number 3824469 to pull the fuel injection pump drive gear loose from the fuel pump drive shaft.

Remove the four mounting nuts that hold the fuel pump to the gear housing.

Remove the fuel pump.

The dowel pin in the fuel pump drive shaft must not be sheared.

If the dowel is sheared, the camshaft housing or fuel pump must be replaced, and the drive gear must be replaced.

Be sure the pilot o-ring is not cut or otherwise damaged.

Be sure the pump oil supply o-ring is not damaged.

Make sure the engine is at Number 1 cylinder, top dead center. The fuel pump gear timing mark must align with the top dead center mark on the front cover.

Make certain the o-ring seals for the oil feed orifice (A) and pilot (B) are correctly installed.

Lubricate the pilot o-ring (B) with clean engine oil.

Clean the nose of the drive shaft and the fuel pump gear inside diameter with contact cleaner, Part Number 3824510 or equivalent.

The fuel pump drive gear inside diameter and the drive shaft outside diameter must be clean and dry before installing the gear.

Slide the fuel injection pump shaft through the drive gear and position the fuel injection pump flange onto the mounting studs.

Make certain the dowel pin in the drive shaft lines up with the keyway in the fuel injection pump gear.

Installation sequence for fuel pump head mounted support bracket:

1. Install the pump mounting nuts (leave loose).
2. Install the support bracket bolts (leave loose).
3. Tighten the pump mounting nuts.

1. Tighten the support bracket bolts.

Installation sequence for fuel pump actuator housing mounted support bracket:

1. Install the pump mounting nuts (leave loose).
2. Install the bolt to the cylinder head (1) and the bolt through the pump flange (2) into the support bracket (leave loose).
3. Tighten the pump mounting nuts.

1. Tighten the bolt into the cylinder head (1).

1. Tighten the bolt into the pump flange (2).

Tighten the fuel injection pump drive gear nut.

• Install the access cover in the front cover.
• Install the fuel supply lines to the fuel pump. Refer to Procedure 006-024 in Section 6.
• Install the fuel drain line to the fuel pump. Refer to Procedure 006-013 in Section 6.
• Connect the wire harness to the fuel pump actuator.
• Install the fuel filter head bracket (marine applications only. Refer to Procedure 006-018 in Section 6.
• Install the system integration module mounting capscrews and nuts (marine applications only).
• Connect the batteries. Refer to Procedure 013-009 in Section 13.
• Open the fuel supply valve. Refer to the OEM service manual.
• Operate the engine and check for leaks.