Fuel Pump ( ) Table of Contents. Summary. View Related Topic. Summary. General Information Test. Preparatory Steps. Remove.

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1 View Related Topic Fuel Pump ( ) Table of Contents Summary General Information Test Without Electric Lift Pump With Electric Lift Pump Preparatory Steps Marine Applications Remove Rear Gear Train Front Gear Train Marine Applications Disassemble Rear Gear Train Clean and Inspect for Reuse Marine Applications Assemble Install Rear Gear Train Automotive and Industrial Front Gear Train Marine Applications Finishing Steps Prime With Electric Lift Pump Marine Applications Automotive and Industrial With Electric Lift Pump With Hand Priming Pump Marine Applications Summary With the keyswitch ON and the engine cranking, check See detail.

2 the high pressure injection pump. If the engine can be started, a measurement of the fuel return flow can diagnose a high-pressure fuel pump problem. Disconnect the fuel pump return line. 3.9L and 5.9L Engines: Attach the fuel pressure gauge adapter, Part Number , to the fuel pump return fitting. Install a quickdisconnect block-off fitting, Part Number , on the disconnected drain line. 4.5L and 6.7L Engines: Attach the female quick-disconnect fuel drain hose, Part Number , onto the fuel pump drain connection. Install a quick-disconnect block-off fitting, Part Number , on the disconnected drain line. At the fuel return manifold, remove the banjo bolt for fuel pump return line and install test fitting, Part Number For marine engines, the return manifold is located on the side of the engine block, next to the ECM. Place fuel drain hose into graduated beaker, start engine, measure flow. See detail. Disconnect the batteries.

3 Prepare the engine to remove the fuel pump. See detail. Prepare the engine to remove the fuel pump. See detail. Disconnect the high-pressure supply line and the EFC Actuator Valve wire harness connector. Remove the fuel pump from the gear housing. Remove the fuel pump drive access cover. Remove the fuel pump drive gear retaining nut and lock washer. Hold the gear puller while removing the fuel pump drive gear. Remove the fuel pump assembly. Marine Applications: Remove the three fuel pump flanged mounting nuts. Remove the fuel pump drive access cover Remove the fuel pump drive gear retaining nut and lockwasher. Install the spacer, Part Number , onto the fuel pump drive shaft. Install the fuel pump drive gear puller, Part Number , onto the fuel pump drive shaft and gear.

4 Use a ratchet and remove the fuel pump drive gear from the fuel pump drive shaft. Remove the spacer, Part Number , from the fuel pump drive shaft. Remove the fuel pump assembly. Use a fuel pump retention tool to retain the fuel pump drive gear. See detail. Loosen the clamp load of the fuel pump drive gear retaining nut by rotating it counterclockwise. Do not remove it from the shaft. Install a bearing separator, Part Number or equivalent, between the fuel pump mounting flange and drive gear. Secure the bearing separator. Install a snap-on puller onto the bearing separator and the fuel pump driveshaft. See detail. Rotate the puller screw until the drive gear is separated from the driveshaft. Remove the drive gear retaining nut, lockwasher, and drive gear from the fuel pump driveshaft. Clean the fuel pump with solvent. Dry with compressed air. Inspect the driveshaft and gear, the o-ring seal, and the o-ring seal area for damage. Clean and repair any burred

5 surfaces or replace if damage is found. Inspect gear housing, highpressure pump mounting bore, and mounting studs for cracks. Marine: Inspect the driveshaft for damage. Inspect the o-ring seal area for damage. The pump driveshaft nose and drive gear shaft mating surface must be clean and dry prior to assembly. Wipe off the driveshaft and gear with solvent and a lintfree cloth. Do not touch the mating surfaces after wiping. Install the drive gear onto the driveshaft. Install the driveshaft lockwasher and retaining nut and finger tighten. Use the fuel pump gear retention tool, Part Number , and a 1/2 inch breaker bar to hold the drive gear in place while tightening the drive gear retaining nut. Torque: 105 N m [77 ft-lb] Install the fuel pump on the gear housing. Install the fuel pump mounting nuts and tighten. Torque: 25 N m [221 in-lb] Install the high-pressure supply line from the highpressure pump to the fuel rail and tighten the holding brackets. 3.9L and 5.9L High Pressure Supply Line Torque: 30 N m [22 ft-lb] Install the high-pressure supply line from the high- 4.5L and 6.7L High Pressure

6 pressure pump to the fuel rail and tighten the holding brackets. Supply Line Torque: 30 N m [22 ft-lb] Install the drive gear retaining nut and lock washer onto the drive shaft. Tighten the gear retaining nut. Torque: N m 105 [77 ft-lb] Install a new square cut o-ring onto the fuel pump drive access cover. Install the fuel pump drive access cover. Torque: 8 N m [71 in-lb] Wipe off the driveshaft and gear with solvent and a lintfree cloth. Do not touch the mating surfaces after wiping. Install a new seal ring on the front of the fuel pump assembly. Be sure the seal ring is not twisted. Lubricate the seal ring and the mounting bore of the gear housing. P-80 rubber lubricant emulsion, Part Number Install the fuel pump onto the gear housing. Install the three fuel pump to gear housing mounting nuts and tighten. Torque: 25 N m [18 ft-lb] Install the drive gear retaining nut and lock washer onto the drive shaft. Tighten the retaining nut. Torque: 105 N m [77 ft-lb] Install a new square cut o-ring onto the fuel pump drive access cover. Install the fuel pump drive access cover. Prepare the engine for normal operation. See detail.

7 Connect the batteries. Prime the fuel system. Marine: Prepare the engine for normal operation. See detail. Refer to Procedure in Familiarization section for further information. Allow the lift pump to run by turning the key switch ON and waiting 30 seconds before starting. Operate the engine and check for leaks. Dry Fuel Filter and Fuel Tubes: Before starting the engine, pump the hand priming pump 120 times. See detail. Full Fuel Filter and Fuel Tubes: Before starting the engine, pump the hand priming pump 40 times. See detail. Operate the engine and check for leaks. Prime the fuel system. Refer to Procedure See detail. General Information TOC There are four different mounting locations available for high-pressure

8 fuel pumps. The pump can be mounted in a high or low position in either a front or rear gear train engine. Due to the number of different fuel pump mounting locations, the steps in this procedure have been written to be generic. Some of the illustrations do not represent the parts being removed or installed. CAUTION Use caution when disconnecting or removing fuel lines, replacing filters and priming the fuel system, so 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.

9 CAUTION Be sure that the fuel inlet and return valves are returned to the open position before cranking the engine. Engine damage can result if the valves are in the wrong position when the engine is cranked or started. Environmental damage can also occur. Refer to Procedure in Familiarization section for further information. Test TOC CAUTION Clean all fittings before

10 disassembly. Dirt or contaminants can damage the fuel system. With the keyswitch ON and the engine cranking, check the high pressure injection pump. Check the high pressure injection pump fuel flow as follows: Disconnect the high pressure fuel line to the fuel rail from the high pressure injection pump. Connect a clear hose to the outlet of the high pressure injection pump. Run the high pressure fuel line into an empty bucket. Crank the engine for 30 seconds and measure the fuel pump flow. Minimum fuel pump flow is 75 ml

11 [2.5 oz] in 30 seconds at 125 rpm or 90 ml [3.04 oz] in 30 seconds at 150 rpm for 4-cylinder and 6- cylinder engines. If the minimum fuel flow is achieved, the electronic fuel control (EFC) actuator is defective. Refer to Procedure in the ISB e, ISB and QSB (Common Rail Fuel System) Series Engines Service Manual, Bulletin If the minimum fuel flow is not achieved, the highpressure injection pump is defective and needs to be replaced. Summary 1

12 If the engine can be started, a measurement of the fuel return flow can diagnose a highpressure fuel pump problem. The following steps describe how to test the high-pressure fuel pump return flow. WARNING The fuel pump highpressure fuel lines and fuel rail contain very high-pressure fuel. Never loosen any fittings while the engine is running. Personal injury and property damage can result. A malfunctioning fuel return overflow valve or fuel pump can result in high return from the fuel pump. The return fuel flow from the pump must be measured at idle conditions. The fuel system leakage test in the INSITE electronic service tool can be used to increase system pressure and therefore increase the ability to detect high leakage. Summary 2

13 Without Electric Lift Pump Disconnect the fuel pump return line. 3.9L and 5.9L Engines Attach the fuel pressure gauge adapter, Part Number , to the fuel pump return fitting. Install a quickdisconnect blockoff fitting, Part Number , on the disconnected drain line. 4.5L and 6.7L Engines Attach the female quick-disconnect fuel drain hose, Part Number , onto the fuel pump drain connection. Install a quick-disconnect block-off fitting, Part Number , on the disconnected drain line. Summary 3 Summary 4 Summary 5 With Electric Lift Pump Follow the fuel return line from the fuel pump to the fuel return manifold. At the fuel return

14 manifold, remove the banjo bolt for fuel pump return line and install test fitting, Part Number CAUTION If tool Part Number is installed at the fuel pump, it will block return flow and cause possible damage to the fuel pump. Install tool Part Number only at the fuel return manifold. For automotive and industrial applications, the return manifold is located near the top of the engine, beside the fuel rail. Summary 6 For marine engines, the return manifold is located on the side of the engine block, next to the ECM.

15 Summary 7 WARNING Fuel can be returned at highly elevated temperatures. Wear safety glasses and protective gloves and clothing when performing this test. Avoid contact with returned fuel. Place the end of the fuel pressure gauge adapter tool or fuel drain hose into a 500 ml graduated beaker, Part Number Start the engine.

16 Measure the flow rate by recording the amount of time necessary to fill a 400 ml graduated beaker. Flow Specification: Standard Idle Conditions (750 rpm) 4- and 6- cylinder 400 ml (maximum) in 25 seconds Summary 8 Maximum Flow: Standard Idle Conditions (750 rpm) 4- and 6- cylinder 400 ml in 25 seconds Preparatory Steps TOC 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

17 arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Summary 9 Disconnect the batteries. 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. CAUTION Do not vent the fuel system on a hot engine; this can cause fuel to spill onto a

18 hot exhaust manifold, which can cause a fire. Summary 10 CAUTION Drain the fuelwater separator into a container, and dispose of the contents in accordance with local environmental regulations. CAUTION Clean all fittings before disassembly. Dirt or contaminants can damage the fuel system. Disconnect and remove the lowpressure fuel supply and drain lines. Refer to Procedures and For engines with a low mount fuel filter, the fuel filter head must be removed to

19 remove the fuel pump. Refer to Procedure Marine Applications 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

20 the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system. Summary 11 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 draining the fuel system, so that fuel is not spilled or drained into the bilge area. The fuel must be disposed of in accordance with local environmental regulations. Remove the low-pressure

21 fuel supply lines. Refer to Procedure Remove the low-pressure fuel drain lines. Refer to Procedure Apply a countertorque to the fitting on the highpressure pump to reduce the possibility of a leak or a loose fitting. Remove the highpressure supply line from the fuel pump to the fuel rail (flared connection). Disconnect the fuel control actuator electrical connector. Remove the dipstick mounting capscrew and position the dipstick out of the way for pump removal. Remove the valve cover lubrication vent flex hose

22 connector at the engine block mounted adapter. Refer to Procedure Remove the belt guard section located in front of the sea water pump. Refer to Procedure Remove TOC NOTE: A counter-torque must be applied to the fitting on the high pressure pump. This is to prevent the fitting from being loosened and to prevent the possibility of a leak. Disconnect the high-pressure supply line from high-pressure fuel pump to the fuel rail and loosen the holding brackets. Disconnect the EFC Actuator Valve wire Summary 12

23 harness connector. Rear Gear Train Remove the three flanged fuel pump mounting nuts. Remove the fuel pump from the gear housing. Summary 13 Front Gear Train Remove the fuel pump drive access cover with a 3/8-inch drive ratchet. Summary 14

24 CAUTION Place a clean cloth in the airgap between the fuel pump drive gear and the gear cover, or use a screwdriver to prevent the mounting nut and lock washer from being dropped into the front gear train. CAUTION The fuel pump drive gear is captive between the gear housing and the gear cover. Do not rotate the engine while the gear is not supported by the fuel pump drive shaft. The gear, gear housing or gear cover can be damaged. Summary 15 Remove the fuel pump drive gear retaining nut and lock washer.

25 CAUTION Protect the fuel pump drive shaft threads from damage during gear removal. Install the fuel pump drive gear puller onto the drive shaft and gear. Hold the gear puller while removing the fuel pump drive gear. Summary 16 Remove the fuel pump assembly. Summary 17 Marine Applications Remove the three fuel pump flanged

26 mounting nuts. Summary 18 Remove the fuel pump drive access cover with a 3/8-inch drive ratchet. Summary 19 CAUTION Place a clean cloth in the air gap between the

27 fuel pump drive gear and the gear cover, or use a screw driver to prevent the mounting nut and lockwasher from being dropped into the front gear train. CAUTION The fuel pump drive gear is captive between the gear housing and the gear cover. Do not rotate the crankshaft while the gear is not supported by the fuel pump drive shaft. The gear, gear housing or gear cover can be damaged. Summary 20 Remove the fuel pump drive gear retaining nut and lockwasher. Install the spacer, Part Number , from service tool, Part Number , onto the fuel pump drive shaft.

28 Summary 21 CAUTION Protect the fuel pump drive shaft threads from damage while removing the fuel pump gear. Install the fuel pump drive gear puller, Part Number , onto the fuel pump drive shaft and gear. Summary 22 Use a ratchet and remove the fuel pump drive gear from the fuel pump drive shaft.

29 Summary 23 Remove the spacer, Part Number , from the fuel pump drive shaft. Summary 24 Remove the fuel pump assembly.

30 Summary 25 Disassemble TOC Rear Gear Train Use a fuel pump retention tool, Part Number , and a ½-inch breaker bar to retain the fuel pump drive gear. Loosen the clamp load of the fuel pump drive gear retaining nut by rotating it counterclockwise. Do not remove it from the shaft. Summary 26 Summary 27 Install a bearing

31 separator, Part Number or equivalent, between the fuel pump mounting flange and drive gear. Secure the bearing separator. Summary 28 Install a snap-on puller, Part Number CG150-02, or equivalent onto the bearing separator, Part Number , and the fuel pump driveshaft. Rotate the puller screw until the drive gear is separated from the driveshaft. Remove the drive gear retaining nut, lockwasher, and drive gear from the fuel pump driveshaft. Summary 29 Summary 30 Summary 31 Clean and Inspect for Reuse TOC

32 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. WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. CAUTION Use solvent or cleaner that will not harm aluminum.

33 Summary 32 CAUTION Do not allow the cleaner to enter the fuel fittings. Dirt and debris can damage fuel system. Clean the fuel pump with solvent. Dry with compressed air. Inspect the driveshaft and gear for damage. Replace if damage is found. Inspect the o-ring seal for damage. Replace if damage is found. Inspect the o-ring seal area for damage. Clean and repair any burred surfaces. Summary 33 Inspect gear housing, highpressure pump mounting bore, and mounting studs for cracks.

34 Summary 34 Marine Applications Inspect the driveshaft for damage. Replace the fuel pump if damage is found. Inspect the o-ring seal area for damage. Clean and repair any burred surfaces. Summary 35 Assemble TOC

35 The pump driveshaft nose and drive gear shaft mating surface must be clean and dry prior to assembly. Wipe off the driveshaft and gear with solvent and a lint-free cloth. Do not touch the mating surfaces after wiping. Summary 36 Summary 37 Rear Gear Train Install the drive gear onto the driveshaft. Install the driveshaft lockwasher and retaining nut and finger tighten. Summary 38 Use the fuel pump gear retention tool, Part Number , and a 1/2 inch breaker bar to hold the drive gear in place while tightening

36 the drive gear retaining nut. Torque Value: 105 n.m [77 ftlb ] Summary 39 Install TOC Automotive and Industrial Install the fuel pump on the gear housing. NOTE: Timing of the highpressure pump with the crankshaft is not required. Summary 40 Install the fuel

37 pump mounting nuts and tighten. Torque Value: 25 n.m [221 inlb ] Summary 41 Install the highpressure supply line from the highpressure pump to the fuel rail and tighten the holding brackets. NOTE: Apply a counter-torque on the high-pressure pump outlet port to prevent overtightening. 3.9L and 5.9L High Pressure Supply Line 30 n.m [22 ftlb ] 4.5L and 6.7L High Pressure Supply Line 30 n.m [22 ftlb ] Summary 42 Summary 43

38 Connect the EFC actuator valve wire harness connector. Front Gear Train CAUTION Place a clean cloth in the airgap between the fuel pump drive gear and the gear cover, or use a screw driver to prevent the mounting nut and lock washer from being dropped into the front gear train. CAUTION The fuel pump drive gear is captive between the gear housing and the gear cover. Do not rotate the engine while the gear is not supported by the fuel pump drive shaft. The gear, gear housing or gear cover can be

39 damaged. NOTE: The engine barring tool, Part Number , can be used to prevent the crankshaft from rotating while tightening the retaining nut. Install the drive gear retaining nut and lock washer onto the drive shaft. Tighten the gear retaining nut. Summary 44 Torque Value: 105 n.m [77 ftlb ] Install a new square cut o-ring onto the fuel pump drive access cover. Install the fuel pump drive access cover with a 3/8- inch drive ratchet. The plate is threaded into the gear cover. Torque Value: 8 n.m [71 inlb ] Summary 45 Marine Applications

40 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. WARNING Some solvents are flammable and toxic. Read the manufacturer's instructions before using. The fuel pump driveshaft nose and drive gear shaft mating surface must be clean and dry prior to installation. Wipe off the driveshaft and gear with solvent and a lint-free cloth. Do not touch the Summary 46

41 mating surfaces after wiping. Install a new seal ring on the front of the fuel pump assembly. Be sure the seal ring is not twisted. Lubricate the seal ring and the mounting bore of the gear housing with P-80 rubber lubricant emulsion, Part Number Summary 47 Summary 48 Install the fuel pump onto the gear housing. Install the three fuel pump to gear housing mounting nuts and tighten. Torque Value: 25 n.m [18 ftlb ] Summary 49 Summary 50 CAUTION

42 Place a clean cloth in the air gap between the fuel pump drive gear and the gear cover, or use a screw driver to prevent the mounting nut and lockwasher from being dropped into the front gear train. CAUTION The fuel pump drive gear is captive between the gear housing and the gear cover. Do not rotate the crankshaft while the gear is not supported by the fuel pump drive shaft. The gear, gear housing or gear cover can be damaged. NOTE: The engine barring tool, Part Number , can be used to prevent the crankshaft from rotating while tightening the retaining nut. Install the drive Summary 51

43 gear retaining nut and lock washer onto the drive shaft. Tighten the retaining nut. Torque Value: 105 n.m [77 ftlb ] Install a new square cut o-ring onto the fuel pump drive access cover. Install the fuel pump drive access cover with a 3/8-inch drive ratchet. The plate is threaded into the gear cover. Summary 52 Finishing Steps TOC With Electric Lift Pump For engines with a low mount fuel filter, install the fuel filter head. Refer to Procedure Install the low

44 pressure fuel supply lines. Refer to Procedure Install the low pressure fuel drain lines. Refer to Procedure Summary 53 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. Connect the batteries. Summary 54

45 Prime the fuel system. See the Prime step in this procedure. Marine Applications 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

46 the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system. Summary 55 Install the valve cover lubrication vent flex hose connection at the block mounted adapter. Refer to Procedure Apply a countertorque to the fitting on the highpressure pump to reduce the possibility of a leak or a loose fitting. Install the highpressure fuel supply line from the fuel pump to the fuel rail (flared connection). Install the low-pressure fuel supply lines. Refer to Procedure Install the

47 low-pressure fuel drain lines. Refer to Procedure Connect the fuel control actuator electrical connector. Install the belt guard section located in front of the sea water pump. Refer to Procedure Connect the batteries. Refer to Procedure Prime the fuel system. See the Prime step in this procedure. Operate the engine and check for leaks. Prime TOC Automotive and Industrial WARNING

48 The fuel pump highpressure fuel lines and fuel rail contain very high-pressure fuel. Never loosen any fittings while the engine is running. Personal injury and property damage can result. CAUTION Be sure that the fuel inlet and return valves are returned to the open position before cranking the engine. Engine damage can result if the valves are in the wrong position when the engine is cranked or started. Environmental damage can also occur. CAUTION Use caution when disconnecting or removing fuel lines, replacing filters and priming the fuel system, so that fuel Summary 56

49 is not spilled or drained. The fuel and fuel filters must be discarded in accordance with local environmental regulations. Refer to Procedure in Familiarization section for further information. With Electric Lift Pump Allow the lift pump to run by turning the key switch ON and waiting 30 seconds before starting. NOTE: It is not necessary to vent air from the highpressure fuel system before starting the engine. Cranking the engine will prime the fuel system. Operate the engine and check for leaks. Summary 57 Summary 58 With Hand Priming Pump Dry Fuel Filter and Fuel Tubes: this condition occurs if the engine has come from the manufacturing plant without being tested before shipping, if the fuel

50 filters have been changed. Before starting the engine, pump the hand priming pump 120 times. Full Fuel Filter and Fuel Tubes: This condition occurs if the engine is being installed for the first time after being built, but was tested at the manufacturing plant or is being reinstalled. Before starting the engine, pump the hand priming pump 40 times. NOTE: NOTE: It is not necessary to vent air from the highpressure fuel system before starting the engine. Cranking the engine will prime the fuel system. Operate the engine and check for leaks. Summary 59 Summary 60 Summary 61 Marine Applications WARNING

51 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. CAUTION Use caution when disconnecting or removing fuel lines, replacing filters and priming the fuel system, so 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. CAUTION Failure to properly prime the fuel system on marine

52 engines can result in damage to the fuel cooler. Be sure the drain valve(s) are open. Be sure a good flow of fuel is present through the fuel cooler by cycling the keyswitch at least five times before starting the engine. Summary 62 NOTE: It is not necessary to vent air from the highpressure fuel system before starting the engine. Cranking the engine will prime the engine. The fuel transfer pump is initiated by turning the keyswitch to the ON position. The pump will run for 50 to 60 seconds, then shut off. Priming the fuel system requires cycling the keyswitch several (5 or more) times to make sure the fuel filter is primed properly and that all the air is out of the fuel system, down stream through the fuel cooler. Last Modified: 27-Feb-2006 Copyright 2006 Cummins, Inc.

53 All rights reserved

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