ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 006-052   Fuel Connector (Head Mounted)

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  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 sever personal injury or death when working on the fuel system.

WARNING  The pressure of the fuel in the line is sufficient to penetrate the skin and cause serious personal injury. Wear gloves and protective clothing.

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.
• Shut off the fuel supply and drain valves. Refer to the OEM service manual.
• Remove the high-pressure fuel supply lines. Refer to Procedure 006-051 in Section 6.

Use fuel connector puller, Part Number 3825157, to remove the fuel connector from the cylinder head.

Remove the fuel connector retaining nut.

Use fuel connector puller, Part Number 3164025, to remove the fuel connector from the cylinder head.

A new high-pressure connector must be installed if a new injector is being installed.

Inspect the fuel connector. Look for burrs or deformation around the inlet and outlet sides of the connector.

Check the edge filter for signs of plugging or material contamination. Do not reuse a high-pressure fuel connector if debris is present.

Check the o-ring for tearing or deterioration.

Inspect the outlet sealing surface of the high-pressure connector for wear, an uneven seating surface, or signs of leakage.

When a high-pressure fuel leak is present, small lines or cuts in the connector will be eroded into the seating surface.

The high-pressure connector and injector must be replaced when this condition is observed.

Coat the fuel connector o-ring with clean engine oil.

NOTE: If a new injector has been installed, a new fuel connector must be used.

Carefully push the fuel connector into the head until it stops against the injector. Be certain the injector is fully seated in the injector bore before installing the fuel connector. Refer to Procedure 006-026 in Section 6.

NOTE: If a new injector has been installed, a new fuel connector must be used.

Lubricate the fuel connector o-ring and the threads on the fuel connector retaining nut.

Carefully insert the fuel connector, aligning the guide pin with the slot in the cylinder head at the 12-o’clock position.

NOTE: If the injector was removed along with the high-pressure fuel connector, the installation steps must be followed. Refer to Procedure 006-026 in Section 6.

Tighten the fuel connector retaining nut.

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 high-pressure fuel supply lines. Refer to Procedure 006-051 in Section 6.
• Open the fuel supply and drain valves. Refer to the OEM service manual.
• Connect the batteries. Refer to Procedure 013-009 in Section 13.
• Operate the engine and check for leaks.