ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 005-226   Fuel Pump Head Outlet Fitting

WARNING  The fuel pump, high-pressure fuel lines, and fuel rail contain very high-pressure fuel. Do not loosen any fittings while the engine is running. Wait at least 10 minutes after shutting down the engine before loosening any fittings in the high-pressure fuel system to allow pressure to decrease to a lower level.

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 or dirt can cause personal injury.

WARNING  Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system.

WARNING  Do not vent the fuel system on a hot engine; this can cause fuel to spill onto a hot exhaust manifold, which can cause a fire.

CAUTION  Use caution when disconnecting or removing fuel lines, replacing filters and priming the fuel system that fuel is not spilled or drained into the bilge area. Do not drop or throw filter elements into the bilge area. The fuel and fuel filters must be discarded in accordance with local environmental regulations.

• Disconnect the batteries. Refer to Procedure 013-009 in Section 13.
• Thoroughly clean the entire fuel pump. Dry the fuel pump with compressed air.
• Close the fuel supply valve. Refer to the OEM service manual.
• Remove the high-pressure fuel line from the fuel pump actuator housing. Refer to Procedure 006-051 in Section 6.
• Remove the fuel drain line from the actuator housing. Refer to Procedure 006-013 in Section 6.
• Remove the fuel supply line from the fuel pump actuator housing. Refer to Procedure 006-024 in Section 6.
• Remove the fuel pump actuator housing from the high-pressure fuel pump. Refer to Procedure 005-228 in Section 5.

Remove the fuel pump head outlet fitting and the seal washer from the threaded hole in the back of the high-pressure pump head.

NOTE: It is necessary to remove the seal washer with the aid of a tapered punch. Insert a tapered punch into the center of the seal washer and work the seal out from the bore in the back of the high-pressure pump head.

Clean the threaded hole in the high-pressure pump head with contact cleaner, Part Number 3824510, or equivalent.

Inspect the threads and cavity in the high-pressure pump head for burrs or debris.

Inspect the seal washer end of the outlet fitting. There should be a polished crown that is free of nicks or inclusions. If the crown is damaged or severely flattened, the male union must be replaced.

Clean any burrs with a wire brush, then flush the bore clean.

NOTE: This joint is designed to seal in excess of 179,264 kPa [26,000 psi]. Seal washers must not be reused.

Install a new seal washer onto the outlet fitting. The seal washer should pilot into the outlet fitting. A small amount of clean grease, such as assembly lubricant, will help in keeping the seal attached to the outlet fitting during installation.

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.

• Install the fuel pump actuator housing to the high-pressure fuel pump. Refer to Procedure 005-228 in Section 5.
• Install the high-pressure fuel line to the fuel pump actuator housing. Refer to Procedure 006-051 in Section 6.
• Install the fuel drain line to the actuator housing. Refer to Procedure 006-013 in Section 6.
• Install the fuel supply line to the fuel pump actuator housing. Refer to Procedure 006-024 in Section 6.
• Open the fuel supply valve. Refer to the OEM service manual.
• Connect the batteries. Refer to Procedure 013-009 in Section 13.
• Operate the engine and check for leaks.
• Perform several throttle snaps so that increased fuel rail pressure may be developed.