ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 006-060   Fuel Rail

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  The pressure within the fuel rail is extremely high. High pressure can penetrate the skin. Stand clear of the engine while it is running.

WARNING  The fuel pump high-pressure fuel lines and fuel rail contain very high-pressure fuel. To reduce the possibility of personal injury and property damage, never loosen any fittings while the engine is running.

Inspect the fuel pressure sensor, high-pressure fuel line connections, and male unions for leaks.

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 can 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.

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  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

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.
• Disconnect the fuel pressure sensor from the engine wiring harness. Refer to Procedure 019-115 in Section 19. This procedure is found in the Troubleshooting and Repair Manual, CM850 Electronic Control System, ISC and ISL Engines, Bulletin 4021416.
• Remove the high-pressure fuel lines from the fuel rail. Refer to Procedure 006-051 in Section 6.
• Remove the fuel drain line from the fuel pressure relief valve. Refer to Procedure 006-013 in Section 6.

Remove the capscrews that secure the fuel rail to the cylinder head.

Remove the fuel rail assembly.

Install the fuel rail assembly. Follow the proper sequence to make sure that high-pressure fuel lines are properly aligned.

• Install the fuel rail assembly capscrews finger-tight.
• Install the high-pressure fuel lines finger-tight.
• Tighten the fuel rail assembly capscrews.

• Tighten the high-pressure fuel lines. Refer to Procedure 006-051

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 drain line to the fuel pressure relief valve. Refer to Procedure 006-013 in Section 6.
• Install the fuel pressure sensor to the engine wiring harness. Refer to Procedure 019-115 in Section 19. This procedure can be found in the Troubleshooting and Repair Manual, CM850 Electronic Control System, ISC and ISL Engines, Bulletin 4021416.
• 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.