Best CAPS QSL9.pdf

8/10/2019 Best CAPS QSL9.pdf

http://slidepdf.com/reader/full/best-caps-qsl9pdf 1/56

Section 10Chapter 12

7-89411NH

24 Valve, 8.3 Liter Engine

Fuel System

Note: All coding used in the 8.3 Liter and 9 Liter engine manuals are Cummins engine codes. These

engine codes have no meaning to New Holland warranty codes and should only be used for procedure

steps.






Fuel System Page a

7-89411NH Section 10 Chapter 12 Issued 8-2001

Fuel System

Contents

Engine Fuel Heater, Electric (005-008) ........................ ..................... ...................... .......................... ................... ..................... ................... . 7

Initial Check (005-008-001) ................. ...................... ..................... ..................... ........................ ................... ..................... ............. 7Remove (005-008-002) .................. ...................... ........................ ................... ..................... .......................... ..................... ............. 7

Flow Diagram, Fuel System .................................... ................... ...................... ..................... ..................... ................... ...................... .......... 4

Fuel Flow (005-011) ................... ...................... ..................... ...................... ..................... ....................... .................... ................... ................. 9Pressure Test (005-011-013) ..................... ........................ ................... ..................... ............................. ..................... ................... . 9

Fuel Lift Pump (005-045) .................... ..................... ...................... ................... .......................... ................... ..................... ................... ...... 19

Initial Check (005-045-001) ................. ...................... ..................... ..................... ........................ ................... ..................... ........... 19

Install (005-045-026) .................... ..................... ...................... ................... ..................... ........................ ..................... .................. 21

Remove (005-045-002) .................. ...................... ........................ ................... ..................... .......................... ..................... ........... 20

Test (005-045-012) ................. ...................... ..................... ..................... ................... .......................... ................... ...................... . 20

Fuel Pump (005-016) .................... ................... ................... ..................... ................... ........................ ................... ..................... .................. 10Install (005-016-026) .................... ..................... ...................... ................... ..................... ........................ ..................... .................. 11

Remove (005-016-002) .................. ...................... ........................ ................... ..................... .......................... ..................... ........... 10

Fuel Pump Accumulator (005-077) .................. ...................... ..................... ..................... ........................ ................... ........................ ........ 23

Pressure Test (005-077-013) ..................... ........................ ................... ..................... ............................. ..................... .................. 23

Fuel Pump Accumulator Module (005-085) ...................... ..................... ...................... ................... .......................... .................. ................ 32

Remove (005-085-002) ...................... ..................... ...................... ..................... .......................... ................. ................... ............... 32

Install (005-085-026) ....................... ...................... ..................... ................... .......................... ...................... ................... ............... 35

Fuel Pump Cam Housing (005-080) ................. ...................... ..................... ................... .......................... ................... ..................... ........... 25

Inspect for Reuse (005-080-007) .................... ........................ ................... ..................... ........................ ..................... .................. 25

Fuel Pump Cam Housing Module (005-088) .................. ...................... ..................... ................... ........................ ..................... .................. 43Remove (005-088-002) ...................... ..................... ...................... ..................... .......................... ................. ................... ............... 43

Install (005-088-026) ....................... ...................... ..................... ................... .......................... ...................... ................... ............... 45

Fuel Pump Delivery Valve (005-020) ................... ..................... ..................... ................... .......................... ........................ ................... ...... 14Leak Test (005-020-014) ........................ ..................... ..................... ................... ............................. ..................... ................... ...... 16

Inspect for Reuse (005-020-007) .................... ........................ ................... ..................... ........................ ..................... .................. 14

Install (005-020-026) .................... ..................... ...................... ................... ..................... ........................ ..................... .................. 15

Preparatory (005-020-000) ....................... ........................ ................... ..................... .......................... ..................... ...................... . 14

Remove (005-020-002) .................. ...................... ........................ ................... ..................... .......................... ..................... ........... 14

Fuel Pump Distributor Inlet Fitting (005-084) ..................... ...................... ..................... ........................ ..................... ..................... ........... 29

Remove (005-084-002) ...................... ..................... ...................... ..................... .......................... ................. ................... ............... 29

Install (005-084-026) ....................... ...................... ..................... ................... .......................... ...................... ................... ............... 30

Fuel Pump Distributor Module (005-086) ..................... ..................... ...................... ................... .......................... ..................... .................. 37

Remove (005-086-002) ...................... ..................... ...................... ..................... .......................... ................. ................... ............... 37

Install (005-086-026) ....................... ...................... ..................... ................... .......................... ...................... ................... ............... 38




Page b Fuel System


Fuel Pump Gear Pump (005-025) ..................... ..................... ..................... ...................... .......................... ................... ..................... ......... 16

Measure (005-025-010) ...................... ....................... ...................... ..................... .......................... ..................... ................... ....... 16

Preparatory (005-025-000) ........................ ....................... ...................... ..................... .......................... ................... ..................... 16

Fuel Pump Gear Pump Module (005-089) ...................... ..................... ...................... ..................... ........................ ................... .................. 47

Remove (005-089-002) ..................... ...................... ..................... ..................... ................... .......................... ................... .............. 47

Install (005-089-026) .................... ........................ ................... ...................... .......................... ..................... ................... ................ 48

Fuel Pump Injection Control Valve (005-087).. ....................... ...................... ................... .......................... ................... ....................... ....... 42

Fuel Pump Rate Shape Tube (005-090)................ ...................... ..................... ..................... ........................ ..................... ................... ....... 50

Remove (005-090-002) ..................... ...................... ..................... ..................... ................... .......................... ................... .............. 50

Install (005-090-026) .................... ........................ ................... ...................... .......................... ..................... ................... ................ 51

Fuel Pump Timing (005-037) .................. ..................... ...................... ..................... .......................... ................... ...................... .................. 17

Inspect for Reuse (005-037-007) ........................ ...................... ..................... ..................... .......................... ................. ................ 18

Install (005-037-026) ................... ........................ ...................... ..................... .......................... ................... ................... ................ 18

Remove (005-037-002) .................... ...................... ..................... ..................... ................... .......................... ................... .............. 17

Fuel System - General Information ................................. ...................... ................... ..................... ..................... ................... ...................... . 1

General Information .................... ...................... ..................... ................... ...................... ....................... ...................... ................... . 1

Injection Control Valve (005-078) .................... ..................... ..................... ...................... .......................... ................... ..................... ......... 23

Click Test (005-078-072) .................... ..................... ..................... ...................... .......................... ................... ..................... ......... 23

Pumping Control Valve (005-079) ................. ...................... ..................... ..................... ........................ ..................... ................... .............. 24Click Test (005-079-072) .................... ..................... ..................... ...................... .......................... ................... ..................... ......... 24

Cutout Test (005-079-073) .................... ..................... ...................... ................... .......................... ................... ..................... ......... 24

Rotor, CAPS Fuel Injection Pump (005-072) ........... ................... ........................ ................... .......................... ................... ....................... 22

Inspect for Reuse ................. ...................... ................... ..................... ................... ........................ ................... ..................... ......... 22

Install (005-072-026) ................... ........................ ...................... ..................... .......................... ................... ................... ................ 23

Leak Test (005-072-014) ................. ........................ ..................... ...................... .......................... ................... ..................... ......... 23

Preparatory (005-072-000) ........................ ....................... ...................... ..................... .......................... ................... ..................... 22

Remove (005-072-002) .................... ...................... ..................... ..................... ................... .......................... ................... .............. 22

Service Tools .................. ................... ...................... ................... ................... ....................... ........................ ................... ..................... ......... 6

Fuel System .................. ...................... ................... ..................... ..................... ...................... ................... ..................... .................. 6

Snubber, Rate Shape (005-081) .................... ........................ ................... ..................... ........................ ..................... ................... .............. 25Inspect for Reuse (005-081-007) ........................ ...................... ..................... ..................... .......................... ................. ................ 26

Install (005-081-026) ................... ........................ ...................... ..................... .......................... ................... ................... ................ 27

Leak Test (005-081-014) ................. ........................ ..................... ...................... .......................... ................... ..................... ......... 26

Preparatory (005-081-000) ........................ ....................... ...................... ..................... .......................... ................... ..................... 25

Remove (005-081-002) .................... ...................... ..................... ..................... ................... .......................... ................... .............. 26

Specifications ................. ................... ...................... ................... ..................... ..................... ...................... ................... ..................... ........... 5

Fuel System .................. ...................... ................... ..................... ..................... ...................... ................... ..................... .................. 5



24 Valve, 8.3 Liter Engine Fuel System - General Information

Fuel System Page 1


Fuel System - General Information

General Information

CAPS Fuel Pump Familiarization

The CAPS fuel system is a distributor type injection system. CAPSstands for Cummins Accumulator Pump System. An accumulator is

used to store pressurized fuel for the injection event. There are four

components that provide or receive input to the electronic control mod-

ule (ECM). There are two pumping control valves (1) which are con-

trolled by the ECM. These valves control the pressure in the

accumulator. The accumulator fuel pressure/temperature (2) sensor is

located on the accumulator and provides the ECM with pressure and

temperature information. The Injection Control Valve (3) is also con-

trolled by the ECM and regulates fueling and timing.

The CAPS injection pump can be divided into six distinct units/mod-

ules. They are the gear pump, cam and housing, accumulator/pumping

plunger, rate shape tube, injection control valve (ICV), and distributor.Fuel flows through the modules in the following order;

1. gear pump

2. cam and housing

3. accumulator

4. rate shape tube

5. injector control valve (ICV)

6. distr ibutor

A lift pump is used for priming the pump at start up. The lift pump runs

for approximately 30 seconds after key-on. Once the engine is started,the gear pump is able to maintain prime without any assistance from

the lift pump.

1. fuel filter

2. lift pump

3. fuel tank

The gear pump supplies fuel to the pumping plungers through internal

drillings in the cam housing. The gear pump also supplies fuel to the

distributor for lubrication and injection line refill purposes. The gear

pump is regulated to approximately 180 psi at 2400 engine rpm. The

gear pump has an internal filter to catch any debris generated down-

stream of the main, external fuel filter. The pump camshaft is driven off

the engine camshaft (just like the Bosch pump), therefore pump rpm is

one-half engine rpm. The gear pump is driven by the pump camshaft

via an internal coupling. The gear pump shaft drives the distributor ro-

tor.



Fuel System - General Information 24 Valve, 8.3 Liter Engine

Page 2 Fuel System


Each pumping plunger is driven by a two lobed camshaft with three lift

profiles per lobe. The camshaft pump is located in the cam housing

module. The bearings that support the camshaft as well as the tappets,

rollers, and camshaft itself are lubricated with engine oil. These are the

only components in the pump lubricated with engine oil.

The volume above each pumping plunger is filled, by the gear pump,

as the plungers travel downwards. A pumping control valve (PCV) is lo-

cated above each pumping plunger. The supply fuel from the gear

pump flows around the plunger of this normally open valve into the

chamber above the plunger. As the plunger starts to move upwards the

fuel is pushed backwards into the gear pump. The time at which thepumping control valve is energized (closed) is based on engine speed,

accumulator pressure, and throttle position. When the pumping control

valve closes, the fuel is pushed into the accumulator and then held by

check valves. A zero to 24000 psi pressure sensor is located in the ac-

cumulator. The pressure sensor provides direct feed back to the ECM,

so the desired accumulator pressure is maintained. This pressure sen-

sor also has temperature sensing capabilities built into it. Fuel moves

from the accumulator to the distributor via the rate shape tube.

Fuel is delivered to the injection control valve (ICV) by the rate shape

tube through a drilling in the distributor. The ICV controls both fueling

and timing. The injection control valve contains an inner pin and outervalve. The outer valve is fastened to an armature which is driven by the

magnetic force of an ECM controlled stator. The inner pin is driven by

two methods, spring force and fuel pressure. When the two pins are in

the closed position no fuel flows through the control valve. When the

stator is energized the outer valve is drawn towards the stator. The in-

ner pin is forced to travel with the outer pin by a spring. The inner pin

only travels about half the distance the outer pin does and comes to

rest against a stop. Once the two pins separate fuel can flow to drain

or to the injectors. The pressure of this fuel forces the inner pin to move

back to the starting position. When the outer pin seats against its seat

the flow path to the drain is closed and fuel is directed to the injector

through the distributor. The injection control valve goes through this

process once for each injection event.



24 Valve, 8.3 Liter Engine Fuel System - General Information

Fuel System Page 3


The distributor directs the fuel to the correct injector. The drain fuel

from the ICV is routed through the ICV pressure regulator and is re-

turned to the tank.



Flow Diagram, Fuel System 24 Valve, 8.3 Liter Engine

Page 4 Fuel System


Flow Diagram, Fuel System

1. Fuel from Supply Tank

2. Electronic Lift Pump

3. Fuel Filter and Water Separator

4. Fuel Drain Line

5. CAPS Injection Pump

6. Distributor Outlet Fitting

7. High Pressure Supply Lines

8. Fuel Connector

9. Injectors

10. Fuel Return to Supply Tank



24 Valve, 8.3 Liter Engine Specifications

Fuel System Page 5


Specifications

Fuel System

Engine Idle Speed ......................................................................................................................................................................850 to 950 rpm

Minimum Lift Pump Inlet Pressure at Rated (vacuum) .................. ................... ................... ........................ ................... ... 102 mm Hg [4 in Hg]

Maximum Fuel Filter Outlet Pressure at Rated (vacuum) .................. ................... ................... ..................... .................... 102 mm Hg [4 in Hg]

Minimum Fuel Filter inlet Pressure during Cranking ......... ................... ...................... ..................... ..................... ............. 102 mm Hg [4 in Hg]

Fuel Drain Line Maximum Pressure..................... ...................... ................... ..................... ..................... ................... ..... 254 mm Hg [10 in Hg]

Fuel Inlet Maximum Temperature................................................................................................................................................... 71°C [160°F]

Engine Minimum Cranking Speed ........ ..................... ........................ ................... ..................... ........................ ................... ................ 150 rpm



Service Tools 24 Valve, 8.3 Liter Engine

Page 6 Fuel System


Service Tools

Fuel System

The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate pro-

cedure.

Tool No. Tool Description Tool Illustration

CNH299110 Fuel Pump Gear Puller

Used to pull the fuel pump gear.







24 Valve, 8.3 Liter Engine Fuel Flow (005-011)

Fuel System Page 9


Install the fuel filter.

Connect fuel heater.

Connect water-in-fuel (WIF) sensor if equipped.

Fuel Flow (005-011)

Pressure Test (005-011-013)

Remove the plug from the inlet and outlet side of the fuel filter head.

Install two 10 mm [0.39 in] Compucheck fittings and a pressure gauge

that has a range of at least zero to 2.90 kPa [zero to 20 psi].

Run the engine loaded at rated conditions. Fuel supply restriction

should read as follows:

Pressure drop across the fuel filter should equal 0.725 kPa [5 psi] max-

imum. Outlet side of the filter should equal 2.96 kPa [10 psi] minimum

with the keyswitch in the ON position.



Fuel Pump (005-016) 24 Valve, 8.3 Liter Engine

Page 10 Fuel System


If the maximum fuel pressure drop across the fuel filter is greater than

0.725 kPa [5 psi], replace the fuel filter. Refer to Procedure 006-015.

If the restriction is too high, the supply lines from the fuel supply tank

need to be checked. Refer to Procedure 006-020.

Fuel Pump (005-016)

Remove (005-016-002)

• Disconnect the injection pump supply line. Refer to Procedure

006-024.

• Remove the injector supply lines. Refer to Procedure 006-051.

• Disconnect the tank return line. Refer to Procedure 006-013.

• Disconnect the pumping control valve 4-pin Deutsch connector.

• Disconnect the injection control valve 4-pin Deutsch connector.

• Disconnect the accumulator pressure/temperature sensor.

Remove the injection pump upper support bracket.

Remove the injection pump tail support bracket.

Remove the access cap and gear retaining nut and washer.





Fuel Pump (005-016) 24 Valve, 8.3 Liter Engine

Page 12 Fuel System


Make sure the fuel injection pump is at its TDC position.

The fuel injection pump is at No. 1 cylinder TDC when the dowel pin in

the shaft (A) is perpendicular to the top of the accumulator.

Make sure the o-ring seals for the fill orifice (A) and pilot (B) are cor-

rectly installed and are not damaged.

Lubricate the mounting flange with cleaner.

The fuel pump drive gear inside diameter and the shaft outside diam-eter 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 sure the dowel pin lines up with the keyway in the fuel injectionpump gear.

Make sure the dowel pin in the fuel injection pump flange lines up with

the hole in the gear housing.

Install the mounting nuts.

Install the fuel injection pump upper support bracket.

Install the fuel injection pump tail support bracket.

Torque Value:

Fuel Pump Mounting Nuts 44 N•m [32 ft-lb]

Fuel Pump Support Brackets 44 N•m [32 ft- lb]





Fuel Pump Delivery Valve (005-020) 24 Valve, 8.3 Liter Engine

Page 14 Fuel System


Fuel Pump Delivery Valve (005-020)

Preparatory (005-020-000)

Thoroughly steam clean the distributor snubber and fuel pump area.

Dry with compressed air.

Remove (005-020-002)

Remove the high pressure fuel supply lines. Refer to Procedure 006-

051.

Remove the distributor snubber and the seal disk.

The snubber valve and seat are a matched set; do not mix and match

valves and seats with other snubber assemblies.

If either the snubber valve or seat is damaged, the entire snubber as-

sembly must be replaced. Also, the seal washers must always be re-

placed.

Inspect for Reuse (005-020-007)

Check for broken parts, debris, or sticking of the snubber valve. Re-

place the snubber assembly if any parts are damaged. Always replace

the seal washer.



24 Valve, 8.3 Liter Engine Fuel Pump Delivery Valve (005-020)

Fuel System Page 15


Install (005-020-026)

Install a new seal washer into the distributor outlet fitting hole. Make

sure the washer is fully seated in the bottom of the hole.

Install the snubber assembly hand tight.

Tighten the snubber assemblies.

Torque Value: 81 N•m [60 ft-lb]

Install the high pressure fuel supply lines. Refer to Procedure 006-051.



Fuel Pump Gear Pump (005-025) 24 Valve, 8.3 Liter Engine

Page 16 Fuel System


Leak Test (005-020-014)

Run the engine and check for fuel leaks at the distributor snubbers and

high pressure fuel supply lines.

Fuel Pump Gear Pump (005-025)


Perform fuel inlet restriction test. Refer to Procedure 006-020.

Measure (005-025-010)

Measure outlet pressure at the diagnostic fitting on the CAPS pumpand compare to the following chart.

If pressure is below the minimum values listed and the fuel inlet restric-

tion is satisfactory, inspect the gear pump outlet screen.

Engine Speed (rpm) Gear Pump Pressure (psi)

200 2

700 20

1300 55

2200 120





Fuel Pump Timing (005-037) 24 Valve, 8.3 Liter Engine

Page 18 Fuel System



Check that the fuel pump camshaft alignment dowel is present in the

fuel pump drive gear keyway. If the alignment dowel is not visible, re-

move the injection pump, determine the cause of misalignment, and re-

pair or replace any damaged components.

If this inspection is being performed due to a performance complaint,

and the problem surfaced after gear train removal and replacement,

then check the timing of the camshaft gear to the crankshaft gear and

the camshaft gear to the fuel pump drive gear. Refer to Procedure 001-

012.

Install (005-037-026)

Install and tighten the injection pump camshaft nut.


Install the front gear cover. Refer to Procedure 001-031.



24 Valve, 8.3 Liter Engine Fuel Lift Pump (005-045)

Fuel System Page 19


Fuel Lift Pump (005-045)

Initial Check (005-045-001)

A malfunctioning electric fuel lift pump can cause low power or rough

running from the engine. The fuel lift pump can be cleaned and re-

paired to a limited extent.

CAUTION

Do not operate the fuel system with a suction restriction of more

than 4 in Hg.

Maximum pressure drop across the filter is 34 kPa [5 psi] or 258 mm

Hg [10 in Hg].

The pressure drop will increase as the filter removes contamination

from the fuel.

NOTE: The 24 Valve, 8.3 Liter Engine lift pump is used for initial prime

only.

Check for fuel lift pump operation by turning the vehicle key switch to

the ON position and listening or feeling for operation.

NOTE: Lift pump runs for only 30 seconds at key ON then shuts off.

If the fuel lift pump is not working, check for voltage at the lift pump en-

gine harness connector (9 to 12 volts) after keyswitch is on.

If the voltage does not meet the specifications, check for a good power

supply.



Fuel Lift Pump (005-045) 24 Valve, 8.3 Liter Engine

Page 20 Fuel System


Remove (005-045-002)

Disconnect the battery, negative (-) cable first.

NOTE: Thoroughly clean fittings and components before removal.

Make sure that the debris, water, steam, or cleaning solution does not

reach inside of the fuel system.

Remove the fuel lift pump inlet and outlet fuel lines. Refer to Procedure

006-024.

Disconnect the fuel pump power lead.

10 mm

Remove three capscrews and lift pump from engine block.

Test (005-045-012)

The output of the fuel lift pump can be checked through the following

test.



24 Valve, 8.3 Liter Engine Fuel Lift Pump (005-045)

Fuel System Page 21


Test

Turn the key switch on, measure the output pressure of the fuel lift

pump using pressure gauge at the tap on the outlet port of the lift pump

head.

At initial key-on, the lift pump will run for 30 seconds and then stop.

Measure the fuel inlet restriction before the fuel lift pump.

Measurable restriction is another possible cause for low lift pump pres-

sure. Refer to Procedure 006-020.

Install (005-045-026)

10 mm

Install the fuel lift pump to block using three capscrews.


Connect the power lead to the fuel lift pump.

Install all removed fuel lines. Refer to Procedure 006-024.

Valid Pressure

mm Hg in Hg

508 MIN 20



Rotor, CAPS Fuel Injection Pump (005-072) 24 Valve, 8.3 Liter Engine

Page 22 Fuel System


Rotor, CAPS Fuel Injection Pump (005-072)


Steam clean the fuel injection pump and the engine in the vicinity of the

fuel pump.

Dry with compressed air. Pay special attention to the distributor area.

Bar the engine to TDC using the marks on the gear cover and the fuel

pump drive gear as a guide.

Remove the ignition keys from the ignition or otherwise disable the en-

gine starting system.

Remove (005-072-002)

Remove the distributor plug (1).

NOTE: Do not attempt to start the engine with the distributor plug re-

moved. Doing so could cause the rotor to be ejected from the distribu-

tor, causing damage to the rotor.

Inspect for Reuse

Check the position of the notch on the rotor. It should line-up with the

alignment mark (A) on the outside of the distributor. If the alignment is

correct, the rotor is properly timed to the engine. If a mechanical prob-

lem exists, as indicated by misalignment of the rotor, check fuel pump-

to-engine timing, refer to Procedure 005-037 If pump-to-engine timing

is okay, the distributor module or whole pump will have to be replaced.

Check the o-ring on the distributor plug for damage. Replace if re-

quired.



24 Valve, 8.3 Liter Engine Fuel Pump Accumulator (005-077)

Fuel System Page 23


Install (005-072-026)

Install the distributor plug and torque.


Be sure the rotor is fully engaged before replacing the plug.

Enable the engine starting system.

Leak Test (005-072-014)

Run the engine and check for fuel leaks.

Fuel Pump Accumulator (005-077)

Pressure Test (005-077-013)

Using the electronic service tool, monitor the accumulator pressure

with the engine at idle and under load.

With the engine at an idle, minimum accumulator pressure should be

5000 ± 200 psi.

Under full load the maximum accumulator pressure the pump will de-

velop is 15000 ± 200 psi. If the accumulator pressure is low, replace

the fuel pump accumulator module. Refer to Procedure 005-085.

Injection Control Valve (005-078)

Click Test (005-078-072)

Use an electronic service tool, with the keyswitch in the ON position, to

run the Control Valve Click Test.





24 Valve, 8.3 Liter Engine Fuel Pump Cam Housing (005-080)

Fuel System Page 25


Select the pumping control valve to be cutout.

Select the monitor button and monitor valve close angle (VCA), engine

speed, and accumulator pressure while the selected plunger is cutout.

Record VCA, engine speed, and accumulator pressure after the en-

gine stabilizes.

Cutout the other pumping control valve and record VCA engine speed,

and accumulator pressure after the engine stabilizes.

Compare the results when the rear pumping control valve is cutout,

against the results when the front pumping control valve is cutout.

The VCA should not vary more than 15 degrees crank angle (dca).

If the engine dies when one of the pumping control valves is cutout, re-place the fuel pump accumulator module. Refer to Procedure 005-085.

Troubleshoot any active fault codes before replacing the accumulator

module.

Fuel Pump Cam Housing (005-080)


Inspect the cam housing for any signs of cracks or fuel leakage. Re-

place cam module if necessary, refer to procedure 005-088.

Snubber, Rate Shape (005-081)


Thoroughly steam clean the rate shape tube and fuel pump area.

Dry with compressed air.



Snubber, Rate Shape (005-081) 24 Valve, 8.3 Liter Engine

Page 26 Fuel System


Remove (005-081-002)

Remove the rate shape tube (4) assembly.

Remove the rate shape snubber assembly (2).


Check for broken parts, debris, or sticking of the snubber valve. Re-

place the snubber assembly if any parts are damaged. Always replacethe seal disk.

1. Snubber Valve Seat

2. Spring

3. Rate Shape Snubber Body

4. Seal Disc

5. Snubber Valve

6. Spring Post.

Leak Test (005-081-014)

Run the engine and check for fuel leaks at the rate shape snubber (2)

and rate shape tube (4).



24 Valve, 8.3 Liter Engine Snubber, Rate Shape (005-081)

Fuel System Page 27


Install (005-081-026)

Install a new seal disk into the accumulator.

Apply lube oil to the face of the snubber seat, and to the face and

threads of the snubber fitting.

Install the snubber assembly.

Torque Value: Step 1 14 N•m [10 ft-lb]

Step 2 120 degrees

Install the rate shape tube assembly. Tighten both rate shape tube

nuts.


NOTE: Make sure that the rate shape tube bracket capscrews are

loose. This allows the bracket to align with the rate shape tube.



Snubber, Rate Shape (005-081) 24 Valve, 8.3 Liter Engine

Page 28 Fuel System


Verify rate shape tube isolator capscrew torque.

Torque Value: 8.5 N•m [75 in-lb]

Tighten the rate shape bracket mounting capscrews (1).


Operate the engine and check for leaks.



24 Valve, 8.3 Liter Engine Fuel Pump Distributor Inlet Fitting (005-084)

Fuel System Page 29


Fuel Pump Distributor Inlet Fitting (005-084)

Remove (005-084-002)

Remove the rate shape tube assembly; refer to Procedure 005-090.

17 mm

Remove the distributor inlet fitting.

There are two types of inlet fittings and sealing washers. The new de-

sign is identified by the notches (1) in the flats of the fitting and has a

sealing washer with a raised center (2) and a smaller internal diameter.

Use the appropriate removal steps below, for the type of fitting beingremoved.

No. 4 Spiral Easy Out

New Style Fitting and Washer

Using a plastic hammer, tap the spiral easy out into the center hole of

the sealing washer. Turn the easy out counterclockwise to dislodge

the washer.



Fuel Pump Distributor Inlet Fitting (005-084) 24 Valve, 8.3 Liter Engine

Page 30 Fuel System


3/16 or 1/8-inch Allen Wrench

Old Style Fitting and Washer

The old sealing washer is swagged into the inlet fitting bore during in-

stallation. A special tool can be made to aid in its removal by grinding

the short leg of an Allen wrench so that wrench is no longer than 13

mm [1/2-in] long (measured from the outside of the long leg). This tool

acts as a miniheal bar to pry out the sealing washer without damaging

the back of the hole.

3/16 or 1/8-inch Allen Wrench

Old Style Fitting and Washer

Pry out the old sealing washer using the modified Allen wrench.

Quite a bit of force is required to remove the sealing washer.

Clean (005-084-006)

WARNING

Any debris left in this fitting during assembly will run through the

fuel pump and damage the fuel pump.

Using QD contact cleaner, Part No. 3824510, clean the inlet fitting bore

from the bottom of the bore outward.

Install (005-084-026)

WARNING

Any dirt trapped in this fitting during assembly will run through

the fuel pump and damage the fuel pump.

Use very clean grease to retain the sealing washer to the inlet fitting

while it is being installed into the bore. Use Lubriplate 105, or equiv-

alent.

Install sealing washer into counterbore in the inlet fitting.



24 Valve, 8.3 Liter Engine Fuel Pump Distributor Inlet Fitting (005-084)

Fuel System Page 31


17 mm

Install new inlet fitting and tighten after sealing washer is seated cor-

rectly.

Torque Value:

Step 1 5.7 N•m [50 in-lb]

Step 2 Rotate 120 degrees clockwise

Install the rate shape tube assembly; refer to Procedure 005-090.

Start the engine and check for fuel leaks at the rate shape tube con-

nections.

Road-test the vehicle for at least 1 mile. Recheck for fuel leaks or active

fault codes.



Fuel Pump Accumulator Module (005-085) 24 Valve, 8.3 Liter Engine

Page 32 Fuel System


Fuel Pump Accumulator Module (005-085)


CAUTION

Make sure that steam does not spray directly on the electrical

connections on the top of the accumulator block; or fault codes

will possibly occur.

Thoroughly steam-clean the entire fuel pump.

Dry the fuel pump with compressed air.

Remove (005-085-002)

Remove the fuel pump drive gear cover.

Locate top dead center for cylinder No. 1 by barring the engine slowly

until the line on the pump gear lines up with the line on the gear cover.


Remove the air bleed line; refer to Procedure 006-056.

Remove the fuel pump upper support bracket.



24 Valve, 8.3 Liter Engine Fuel Pump Accumulator Module (005-085)

Fuel System Page 33


Disconnect the 4-pin Deutsch connector for the pumping control

valves.

Disconnect the 4-pin connector from the fuel pressure/temperature

sensor.

13 mm

Remove two of the four capscrews that are located diagonally from one

another.

13 mm

WARNING

Accumulator module weighs 11 kg [25 lb] and is free to move

once the capscrews are removed.

CAUTION

Do not use air tools. The use of air tools will possibly damage the

fuel pump.

Remove the last two capscrews. Alternately loosen the capscrew to

avoid binding. Loosen each capscrew about on turn at a time.

WARNING

Accumulator module weighs 11 kg [25 lb] and is free to move

once the capscrews are removed.

Remove accumulator module.

Use as much care as possible to avoid dislodging the springs from the

bottom of the accumulator.




Page 34 Fuel System


If the springs are dislodged, the ceramic plungers can fall out. The

plungers are matched to each bore. Reseat springs fully onto plunger

barrels.

Do not interchange the plungers.

NOTE: Before replacing a ceramic plunger, special care needs to be

taken to clean it.

Use QD contact cleaner, Part No. 3824510, to clean the plunger.

Remove the two o-rings, and discard them.

Clean (005-085-006)

Clean the small fuel passage using the plastic tube provided with the

contact cleaner.

Use QD contact cleaner, Part No. 3824510.

Clean the o-ring groove and mounting surface on the cam housing and

the accumulator.

Make sure the top of the tappets in the cam housing are clean. Wipe

out debris with a clean towel.



24 Valve, 8.3 Liter Engine Fuel Pump Accumulator Module (005-085)

Fuel System Page 35



Check the tappets for proper alignment.

The tappets have a slot on the side that engages a pin on the engine

side of the cam housing. The pin keeps the roller aligned with the cam-

shaft. Make sure the tappet assembly is properly aligned.

Install (005-085-026)

Install new o-rings.

Apply Lubriplate 105, or equivalent, to the o-ring grooves to hold the

o-rings in place.

WARNING

The ceramic plungers can fall out when removing the plastic caps

or old springs. Do not interchange the plungers. If thy fall out, use

QD contact cleaner, Part No. 3824510, to thoroughly clean theplungers before replacing them.

If replacing the accumulator module with a new one, remove springs

from the old accumulator module.

Fully install the springs on the plunger barrels of the new accumulator

module.

NOTE: Use of two 10 mm x 80 mm studs will aid in the installation.

Install the accumulator module. Use care to avoid dislodging the

springs on the accumulator and the o-rings on the cam housing.




Page 36 Fuel System


CAUTION

Do not use air tools. The use of air tools will possibly damage the

fuel pump.

Install two of the four capscrews.

Draw the accumulator module down evenly.

Only turn each capscrew about one turn at a time.

Make sure the o-rings are still in their grooves before the accumulator

is fully tightened to the cam housing. Use a mirror if necessary.

13 mm

Install remaining two capscrews.

Tighten the four capscrews.


Connect the 4-pin pumping control valve connector.

Connect the 4-pin fuel pressure/temperature sensor.

Install the upper support bracket.

Tighten the capscrews.


Install rate shape tube assembly (1); refer to Procedure 005-090.

Install the air bleed line (2); refer to Procedure 006-056.

Install the drive gear cover.

Start the engine and check for fuel leaks or active fault codes.

Road-test the vehicle for at least 1 mile. Recheck for fuel leaks or active

fault codes.



24 Valve, 8.3 Liter Engine Fuel Pump Distributor Module (005-086)

Fuel System Page 37


Fuel Pump Distributor Module (005-086)


CAUTION


connections on the top of the accumulator block; or fault codes

will possibly occur.


Dry the fuel pump with compressed air.

Remove (005-086-002)

CAPS vise ring, Part No. 3162897

Remove the air bleed line (1); refer to Procedure 006-056.

Remove the fuel pump from the engine; refer to Procedure 005-016.

.

Mount the fuel pump in the vise ring. Orient the pump with the distrib-

utor facing upward to aid in disassembly.


8 mm Allen Wrench, or T45 Torx

CAUTION

The capscrews also fasten the gear pump module. The gear pump

is free to move after the capscrews are removed.

Loosen but do not remove the distributor plug.

Remove the four capscrews on the distributor.



Fuel Pump Distributor Module (005-086) 24 Valve, 8.3 Liter Engine

Page 38 Fuel System


Remove the distributor module.

Remove the drive coupling.

Discard the two o-rings.


Inspect coupling and shaft ends for excessive wear. Wear is typically

found on the inside corners of the coupling groove.

A polished surface is acceptable.

Replace coupling if wear is visible.

Clean (005-086-006)

Clean the mounting surfaces of the distributor and gear pump.


Install (005-086-026)

Install the drive coupling.

Center the coupling on the gear pump shaft.

Apply Lubricate 105, or equivalent, to the coupling to keep it from

sliding in the shaft groove during reassembly.



24 Valve, 8.3 Liter Engine Fuel Pump Distributor Module (005-086)

Fuel System Page 39



Apply Lubriplate 105, or equivalent to o-rings to keep them from fall-

ing out during reassembly.

Make sure the dowel pin is facing up toward the top of the pump.

If the shaft needs to be rotated, install the fuel pump drive nut onto the

shaft to provide a means for rotating the shaft.

CAUTION

The rotor can slide out once the distributor plug is removed.

CAUTION Do not drop the rotor. The entire distributor module will be ruined

and the rotor damage.

Remove the large plug from the end of the distributor.

Do not remove the rotor.

Install the distributor module.

Lightly rotate the rotor with finger-pressure until it drops into the slot in

the drive coupling.

When properly engaged, the notch in the rotor will align with the hole

in the distributor.

If the rotor will not engage, remove the distributor, and reposition the

drive coupling in the center of the shaft.



Fuel Pump Distributor Module (005-086) 24 Valve, 8.3 Liter Engine

Page 40 Fuel System


CAUTION

The rotor must be properly timed to the fuel pump camshaft. Im-

proper assembly will cause the rotor to be 180 degrees out of

time.

If not properly timed, remove the distributor housing, and repeat the

previous step. Make sure the fuel pump camshaft dowel pin is pointing

toward the top of the pump before reinstalling.

T45 Torx

Make sure the o-rings are not pinched.

Install the four distributor capscrews.

Tighten the capscrews.


8 mm Allen Wrench

Install a new o-ring on the distributor plug.

Install the large plug at the end of the distributor.

Tighten the distributor plug.

Torque Value: 14 N•m [120 in-lb]


Install the fuel pump on the engine; refer to Procedure 005-016.








24 Valve, 8.3 Liter Engine Fuel Pump Cam Housing Module (005-088)

Fuel System Page 43


Fuel Pump Cam Housing Module (005-088)


CAUTION


connections on the top of the accumulator block; or fault codeswill possibly occur.


Dry the pump with compressed air.

Remove (005-088-002)

Remove the air bleed line (1); refer to Procedure 006-056.

Remove the fuel pump from the engine; refer to Procedure 005-016.

Mount the fuel pump in the vise ring. Orient the pump with the distrib-

utor facing upward to aid in disassembly.


Remove the accumulator module; refer to Procedure 005-085.

Remove the distributor module; refer to Procedure 005-086.

Remove the gear pump module; refer to Procedure 005-089.


Remove the roller tappets from the cam housing bores.

Inspect the roller surfaces for pitting and wear.

Make sure the roller rotates freely and smoothly.

Replace the cam housing module if the rollers are worn.



Fuel Pump Cam Housing Module (005-088) 24 Valve, 8.3 Liter Engine

Page 44 Fuel System


Inspect the camshaft lobes for pitting and wear.

Replace the cam housing if there is any pitting or wear.

Inspect the tappet bores for scuffing or wear to the housing.

Polishing will occur in vertical bands at many places around the inside

of the bores.

Polish of the bores is acceptable.

Replace the cam housing if there is any scuffing or wear on the bores,

or damage to the guide pins.

Using fingers, make sure the camshaft turns freely. The bearings must

turn smoothly and free during rotation.

Replace the cam housing if the bearings are tight or rough.

Check the camshaft for end play. If any end play can be felt, use a dial

indicator to check it.

If there is more than 0.05 mm [0.002 in] of end play, replace the cam

housing assembly.

Clean (005-088-006)

Clean the mounting surfaces of the cam housing.




24 Valve, 8.3 Liter Engine Fuel Pump Cam Housing Module (005-088)

Fuel System Page 45


Install (005-088-026)

Make sure the timing dowel pin in the camshaft points toward the top

of the fuel pump.

WARNING

The ceramic plungers will possibly fall out when removing the

springs. Do not interchange the plungers. If the plungers fall out,

use QD contact cleaner, Part No. 3824510, to thoroughly clean

them before replacing.

Lubricate the tappets and camshaft lobes with clean 15W-40 engine

oil.

Install the roller tappets into the cam housing.

Install the new springs onto the plunger barrels of the accumulator

module.

Check the tappets for proper alignment.

The tappets have a slot on the side that engages a pin on the engine

side of the cam housing. The pin keeps the roller aligned with the cam-shaft. Make sure the tappet is properly aligned.

Install the gear pump module; refer to Procedure 005-089.

Install the distributor module; refer to Procedure 005-086.

Install the accumulator module; refer to Procedure 005-085.


Install the fuel pump onto the engine; refer to Procedure 005-016.

Install the air bleed line; refer to Procedure 005-056.



Fuel Pump Cam Housing Module (005-088) 24 Valve, 8.3 Liter Engine

Page 46 Fuel System



Road-test the vehicle for at least 1 mile. Recheck for fuel leaks and ac-

tive fault codes.





Fuel Pump Gear Pump Module (005-089) 24 Valve, 8.3 Liter Engine

Page 48 Fuel System


Clean (005-089-006)

Clean the mounting surfaces of the gear pump and cam housing.


Install (005-089-026)

CAUTION

The larger o-rings on either end of the gear pump differ in size.

The longer o-ring goes to the side facing the cam housing.


Apply Lubricate 105, or equivalent, to the o-rings to keep them from

falling out during assembly.

Install the drive coupling.

Center the coupling in the shaft.

Align the gear pump shaft with the drive coupling.



24 Valve, 8.3 Liter Engine Fuel Pump Gear Pump Module (005-089)

Fuel System Page 49


Install the gear pump module.

Make sure the o-rings are not pinched.

Make sure the timing dowel pin is facing toward the top of the fuel

pump.

Install the distributor module; refer to Procedure 005-086.

Install the rate shape tube; refer to Procedure 005-090.

Install the fuel pump on the engine; refer to Procedure 005-016.



Road-test the vehicle for at least 1 mi le. Recheck for fuel leaks or active

fault codes.



Fuel Pump Rate Shape Tube (005-090) 24 Valve, 8.3 Liter Engine

Page 50 Fuel System


Fuel Pump Rate Shape Tube (005-090)


CAUTION

Make sure that direct steam spray stream does not contact the

electrical connections on the top of the accumulator block; faultcodes will possibly occur.


Dry the fuel pump with compressed air

Remove (005-090-002)

10 mm, 19 mm

Loosen the two rate shape tube nuts (1).

Remove the two bracket capscrews (2).

Remove the rate shape tube assembly.

Do not loosen or remove the isolator capscrews (3).


Inspect isolators for signs of wear or cracks.

Replace rate shape tube assembly if any isolator is worn, cracked, or

missing.

Inspect the ends of the rate shape tube for damage.

Clean (005-090-006)

Clean the ends of the rate shape tube.

Clean out the rate shape tube with contact cleaner if debris is suspect-

ed of entering the tube.

Flush any dirt from the snubber fitting and distributor inlet fitting.

Use QD contact cleaner, Part no,. 3824510.



24 Valve, 8.3 Liter Engine Fuel Pump Rate Shape Tube (005-090)

Fuel System Page 51


Install (005-090-026)

8 mm, 19 mm

Install the rate shape tube assembly using the following steps:

Tighten the rate shape tube nuts (1).Torque Value: 46 N•m [34 ft-lb]

NOTE: IF any force is required to flex the rate shape tube in order to

start the tube nuts, the rate shape tube must be replaced with a new

tube.

8 mm, 10 mm

Install the two bracket capscrews.

Tighten the bracket capscrews (2).Torque Value: 41 N•m [30 ft-lb]

NOTE: Isolator capscrew torque is 12 N•m [110 in-lb] if loosened.

Start the engine and check for fuel leaks at the rate shape tube con-

nections.



Template Name: IS_2_colTemplate Date: 2000_01_13_v5.5.6

Documents

Best CAPS QSL9.pdf