QSK23 Series Engines

005-016 Fuel Pump

Pressure TestRemoveClean and Inspect for ReuseInstallPrime

Pressure Test

Use the INSITE™ tool, the vehicle tachometer, or an optical tachometer, Part Number 3377462, to check the fuel pump pressure at a specified rpm. See fuel pressure specifications in this section.

SMALL | MEDIUM | LARGE

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Use pressure gauge and hose assembly capable of 2800 kPa [400 psi] with quick disconnect fitting, Part Number ST-435-7.

Crank the engine at 150 rpm and measure the fuel pressure. The minimum fuel pressure must be 241 kPa [35 psi].

Start the engine and operate at high idle speed. Refer to the table below for specifications.

Minimum Fuel Pressure

Engine High Idle Speed kPa psi

1500 rpm 1779 258

1800 rpm 2117 307


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Minimum Fuel Pressure

Engine High Idle Speed kPa psi

If the fuel pump pressure is not within specifications, check the fuel pump on a fuel pump test stand.


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If the fuel pump pressure is within specifications when checked on a fuel pump test stand, check the injector o-rings for damage. Refer to Procedure 006-026.


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Remove

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 (-)


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battery cable first and attach the negative (-) battery 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 severe personal injury or death when working on the fuel system.

Clean the fuel pump and surrounding area.


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Disconnect the fuel pump inlet hose (1). Disconnect the electronic fuel control valve supply hose (2).


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Remove the four mounting capscrews.

Remove the lower mounting bracket capscrews and remove the fuel pump.

Remove the jaw coupling spider.

Remove and discard the gasket.


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Clean and Inspect for Reuse

Clean the fuel pump mounting surface.


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Inspect the fuel pump body and front support for cracks and other damage.

Inspect the fuel pump assembly for damaged or loose capscrews and fittings.

Inspect the drive coupling lugs for excessive wear or damage.


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Inspect the spider coupling for cracks or damage.


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Install

Install the fuel pump drive coupling, fuel pump gasket, and fuel pump.

Completely install the fuel pump mounting capscrews but do not tighten them.


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Install the fuel pump support bracket.

Tighten the capscrews.

Install the fuel pump inlet hose (1) and the electronic fuel control valve supply hose (2).

Tighten the hoses.

Fuel Pump Inlet Hose (1)

65 n.m [48 ft-lb]

Fuel Supply Hose (2) 90 n.m [66 ft-lb]


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Prime

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.

NOTE: This procedure is normally only required when the fuel pump has been


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changed, the fuel filters are dry, or the fuel system has been drained.

If the fuel supply pump is dirty, clean the outside of the pump near the fuel inlet and

While the engine is cranking, loosen the electronic fuel control valve supply line at the top of the fuel pump. If fuel does not come out of the connection, the pump must be primed.

Tighten the fuel supply line.

Torque Value: 90 n.m [66 ft-lb]


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Remove the fuel pump inlet hose.SMALL | MEDIUM | LARGE

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Use clean fuel and fill the fuel pump.SMALL | MEDIUM | LARGE

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Install the fuel pump inlet hose to the fuel SMALL | MEDIUM | LARGE

pump.

Tighten fuel supply hose.


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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 last.

Connect the battery cables.


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Crank the engine for 20 seconds. If the engine does not start within 20 seconds, wait two minutes and repeat cranking procedure until the engine starts. The engine may run rough until the air is out of the system.


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Operate the engine to normal operating temperature and check for leaks.


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006-026 Injector

Initial CheckMisfire Using Heat Indicator MarkerFlourescent Tracer Dye Test

Preparatory StepsRemoveInspect for ReuseInstallFinishing Steps

Initial Check

Misfire Using Heat Indicator Marker

NOTE: This procedure may not be effective when the symptoms occur only at low idle or when the engine is cold.

WARNING

The engine temperature, when performing in-chassis exhaust temperature testing, can be excessive. To reduce the possibility of serious injury wait until the engine coolant temperature is below 50°C [122°F].


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If the engine exhibits symptoms of a possible injector notfiring, perform the following check:

Operate the engine to normal operating coolant temperature of 80°C [180°F].Stop the engine and allow the exhaust manifold to cool for 10 minutes.Apply a mark (1) using a 204°C [400°F] temperature indicator marker, (Part Number 3165163), on the surface of all exhaust manifold ports. The mark should be as close to the cylinder head as possible, but not directly on the exhaust manifold mounting flange.Start the engine and operate under light load for a short time. Do not operate the engine under heavy load or for an extended period of time as this may cause inaccurate results.


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If the 204°C [400°F] mark melts (1) the color will disappear and leave only a transparent glazed appearance where the mark was. This indicates that the cylinder is operating to a temperature above 204°C [400°F] .

If the 204°C [400°F] mark does not melt (2) the mark color remains present. This indicates that the cylinder is not operating to temperature of 204°C [400°F], indicating a possible injector malfunction. Refer to the trouble shooting tree t062 for additional troubleshooting information.


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NOTE: It is not recommended to use the temperature indicator markers

Flourescent Tracer Dye Test

Run the engine until the water temperature is above 80°C [180°F].


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Remove the fuel pump return and supply lines and install a 50 litre [15 gallon] isolated fuel supply tank.


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Add one unit of fluorescent tracer, Part Number 3376891, to each 38 litres [10 gallons] of fuel.

Preheat the black light.

Remove the rocker lever cover mounting hardware, but do notremove the rocker lever covers.


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Idle the engine for 5 to 10 minutes or until SMALL | MEDIUM | LARGE

normal operating temperature is reached to allow the dye to circulate through the fuel system.

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Shut the engine off.

Immediately remove the rocker lever covers and inspect each cylinder head using the black light.

Some leakage around the injector is normal.


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Replace the injector or injector o-rings if an abnormal amount of leakage is detected.


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Preparatory Steps

Remove the rocker lever assembly. Refer to Procedure 003-009.


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Remove

Remove the injector hold-down capscrew. Remove the injector and clamp.

Use injector removal/installation tool, Part Number 3824830, to remove the injectors. Insert the pin of the tool in the hole provided in the body of the injector. The hole faces the front of the engine.

If the injector removal/installation tool mentioned above is not available, carefully use a pry bar. Pry upward on the injector against the cylinder head.


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Inspect for Reuse

Remove the sealing ring (1) and note the cylinder location.

Sealing rings are available in different thickness sizes to adjust the injector protrusion.

The four new o-rings must be installed and oriented correctly on the injector. Identify the o-rings to install them in the correct grooves.

Remove the o-rings (2, 3, 4, and 5).

Use a lint-free cloth to clean the exterior of the injector.

Carefully check the area where the sealing


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ring touches the injector.

Inspect the o-ring grooves for damage.

Inspect the injector body and cup retainer for cracks or other damage.

Inspect the injector links for damage, excessive wear, and pitting or scoring on the ball ends.

If the link is damaged or pitting/scoring can be seen or felt, the link must be replaced.

O-ring (2) is brown and is smaller in diameter than the other three.

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.

Use solvent when cleaning the filters. The screens mustbe thoroughly dry prior to installation.

Check the rail (6) and timing (7) filter screens for debris, tears, or punctures. Replace the filter screens if damaged or dirty.


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Check the rail (6) and timing (7) filter for proper installation.

Screens must be securely snapped into the correct position.


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Use a small screwdriver to remove the filter screen by gently prying up on the connector clip.


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Wrap the filter screen around the inlet groove.


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Apply pressure on the filter screen connector clip.

A properly secured connector will create a single, snapping sound.


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Install

Use clean 15W-40 engine oil to lubricate the o-rings.


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Install the hold-down clamp on the side of the injector.


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Install the injector and hold-down clamp in the cylinder head.

Use the injector removal/installation tool, Part Number 3824830, to set the injector in the bore.

The slide hammer will make a dull sound when the injector is seated properly.

NOTE: If the injector removal/installation tool, Part Number 3824830, is not available, use a 40 mm [19/16 in] socket with an extension and a rubber mallet to install the injector.


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Use clean 15W-40 engine oil to lubricate the injector hold-down capscrew.

Install the injector hold-down capscrew.

Torque Value:

Step 1 34 n.m [25 ft-lb]

Step 2 Tighten 90°


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Finishing Steps

Install the rocker lever assembly. Refer to Procedure 003-009.

Adjust the valves and injectors. Refer to Procedure 003-006.

Install the rocker lever cover. Refer to Procedure 003-011.


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006-049 Fuel Control Valve Body Assembly

Preparatory StepsRemoveInstallFinishing Steps

Preparatory Steps

Remove the electronic control module (ECM). Refer to Procedure 019-031 in the Troubleshooting and Repair Manual, Electronic Control System, QSK19, QSK23, QSK45, QSK60, and QSK78 Engines, Bulletin 3666113.

Clean the control valve body and the surrounding area.


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Disconnect the fuel supply hose (1), timing pressure line (2), and rail pressure line (3), at the control valve body.


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It is a good service practice to label parts during removal. Identification of the connections at time of removal with a label will aid the installation process.

Label the electrical connections to the actuators, fuel pressure sensors, and ambient air pressure sensor.


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Disconnect the actuator and pressure sensor connections.


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Remove the nuts holding the electrical connections of the fuel shutoff valve coil. Refer to Procedure 019-050 in the Troubleshooting and Repair Manual, Electronic Control System, QSK19, QSK23, QSK45, QSK60, and QSK78 Engines, Bulletin 3666113.


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Remove

Remove the four capscrews. Move the wire harness and brackets away from the control valve body to gain access.

Remove the control valve body assembly.


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Install

Install the four capscrews to secure the control valve body assembly and the wire harness and brackets.



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Finishing Steps

Install the nut that holds the electrical connection post on the fuel shutoff valve coil. Refer to Procedure 019-050 in the Troubleshooting and Repair Manual, Electronic Control System, QSK19, QSK23, QSK45, QSK60, and QSK78 Engines, Bulletin 3666113.


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Install the electrical connection on the fuel shutoff valve. Refer to Procedure 019-050 in the Troubleshooting and Repair Manual, Electronic Control System, QSK19, QSK23, QSK45, QSK60, and QSK78 Engines, Bulletin 3666113.


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Inspect the actuator and pressure sensor connections for dirt and debris.

Use QD contact cleaner, Part Number 3824510, to clean the connections and actuator, if cleaning is required.


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NOTE: If the electrical connections were not labeled for identification purposes during disassembly, verify the types of connections on the wiring diagram.

Connect the actuator and pressure sensor connections.


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Connect the fuel supply hose (1), the timing rail pressure line (2), and the metering rail pressure lines (3) to the control valve body.

Tighten the fuel supply hose (1).

Tighten the timing pressure (2) and rail pressure lines (3).

Fuel Supply Hose (1) 68 n.m [50 ft-lb]

Timing Pressure Line ( 2)

47 n.m [35 ft-lb]

Rail Pressure Line ( 3)

27 n.m [20 ft-lb]


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Install the ECM. Refer to Procedure 019-031 in the Troubleshooting and Repair Manual, Electronic Control System, QSK19, QSK23, QSK45, QSK60, and QSK78 Engines, Bulletin 3666113.


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006-024 Fuel Supply Lines

Preparatory StepsRemove

Tank to Fuel FilterFuel Pump Inlet LineControl Supply Line

Timing Supply LineRail Supply Line

Clean and Inspect for ReuseInstall

Rail Supply LineTiming Supply LineControl Supply LineFuel Pump Inlet LineTank to Fuel Filter

Finishing Steps

Preparatory Steps

Remove as much of the engine wiring harness and brackets as necessary to gain access to the fuel tubes. Refer to Procedure 019-043 in the Fuel System Troubleshooting and Repair Manual, Electronic Control System, QSK19, QSK23, QSK45, and QSK60 Engines, Bulletin 3666113.


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Remove

Use two wrenches to remove the fuel tubes and hoses.

Support the mating fittings with a wrench. Loosen the fuel tube nuts with the other wrench.


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Tank to Fuel Filter

Remove the fuel filter inlet hose and related clamps.


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Fuel Pump Inlet Line

Remove the fuel pump inlet line and line clamp.

Discard the o-rings.


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Control Supply Line

Remove the fuel control supply line and line clamp.

Discard the o-rings.


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Timing Supply Line

Remove the fuel timing supply line and line clamp.

Discard the o-rings and banjo fitting washers.


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Rail Supply Line

Remove the fuel rail supply line and line clamp.

Discard the o-rings and banjo fitting washers.


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Clean and Inspect for Reuse

WARNING

Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.


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Inspect the line for cracks that can cause a pressure loss.

Inspect the metal fuel lines for sharp bends that can cause a pressure restriction.


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Install

Install the new o-rings in the fittings.

The fuel filter outlet, fuel pump inlet, fuel pump outlet, and fuel control module fittings use face seal o-rings.

Make sure the o-rings are properly seated during installation.


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Use two wrenches to install the fuel tubes and hoses.

Support the mating fittings with a wrench. Tighten the fuel tube nuts with the other wrench.


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Rail Supply Line

Install a new o-ring in the rail supply line fitting and new washers on the banjo fittings.

Install the rail supply line.

Sleeve nut 27 mm [20 ft-lb]

Banjo fitting 34 mm [25 ft-lb]


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Timing Supply Line

Install a new o-ring in the timing supply line fitting and new washers on the banjo fittings.

Install the timing supply line and line clamp.

Sleeve nut 47 mm [35 ft-lb]

Banjo fitting 44 mm [32 ft-lb]


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Control Supply Line


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Fuel Pump Inlet Line


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Tank to Fuel Filter


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Finishing Steps

Install the engine wiring harness and brackets, as necessary. Refer to Procedure 019-043 in the Fuel System Troubleshooting and Repair Manual, Electronic Control System, QSK19, QSK23, QSK45, and QSK60 Engines, Bulletin 3666113.


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QSK23 Series Engines