Section 10Chapter 12 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. 7-89411NH 24 Valve, 8.3 Liter Engine Fuel System Page a Fuel System Contents Engine Fuel Heater, Electric (005-008) ......................................................................................................................................................... 7 Initial Check (005-008-001) .............................................................................................................................................................. 7 Remove (005-008-002) .................................................................................................................................................................... 7 Flow Diagram, Fuel System .......................................................................................................................................................................... 4 Fuel Flow (005-011) ........................................................................................................................................................................................ 9 Pressure 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) .................................................................................................................................................................................... 10 Install (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) ............................................................................................................................................... 43 Remove (005-088-002) ................................................................................................................................................................... 43 Install (005-088-026) ....................................................................................................................................................................... 45 Fuel Pump Delivery Valve (005-020) ........................................................................................................................................................... 14 Leak 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 7-89411NH Section 10 Chapter 12 Issued 8-2001 24 Valve, 8.3 Liter Engine Fuel System Page b 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) ............................................................................................................................................................... 24 Click 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) .................................................................................................................................................................. 25 Inspect 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 7-89411NH Section 10 Chapter 12 Issued 8-2001 24 Valve, 8.3 Liter Engine Fuel System Fuel System - General Information Page 1 Fuel System - General Information General Information CAPS Fuel Pump Familiarization The CAPS fuel system is a distributor type injection system. CAPS stands 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 module (ECM). There are two pumping control valves (1) which are controlled 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 controlled by the ECM and regulates fueling and timing. The CAPS injection pump can be divided into six distinct units/modules. 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. 2. 3. 4. 5. 6. gear pump cam and housing accumulator rate shape tube injector control valve (ICV) distributor 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. 2. 3. fuel filter lift pump 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 downstream 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 rotor. 7-89411NH Section 10 Chapter 12 Issued 8-2001 This pressure sensor also has temperature sensing capabilities built into it. When the pumping control valve closes. and camshaft itself are lubricated with engine oil. by the gear pump. accumulator pressure. 8. A pumping control valve (PCV) is located above each pumping plunger. The volume above each pumping plunger is filled. The outer valve is fastened to an armature which is driven by the magnetic force of an ECM controlled stator. These are the only components in the pump lubricated with engine oil. rollers.Fuel System . as the plungers travel downwards. The ICV controls both fueling and timing.General Information Page 2 24 Valve. Fuel is delivered to the injection control valve (ICV) by the rate shape tube through a drilling in the distributor. The injection control valve contains an inner pin and outer valve. and throttle position.3 Liter Engine Fuel System Each pumping plunger is driven by a two lobed camshaft with three lift profiles per lobe. Once the two pins separate fuel can flow to drain or to the injectors. The injection control valve goes through this process once for each injection event. The supply fuel from the gear pump flows around the plunger of this normally open valve into the chamber above the plunger. The camshaft pump is located in the cam housing module. the fuel is pushed into the accumulator and then held by check valves. A zero to 24000 psi pressure sensor is located in the accumulator. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . 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 time at which the pumping control valve is energized (closed) is based on engine speed. spring force and fuel pressure. The inner pin is driven by two methods. The inner pin only travels about half the distance the outer pin does and comes to rest against a stop. so the desired accumulator pressure is maintained. The pressure of this fuel forces the inner pin to move back to the starting position. The pressure sensor provides direct feed back to the ECM. Fuel moves from the accumulator to the distributor via the rate shape tube. The bearings that support the camshaft as well as the tappets. The inner pin is forced to travel with the outer pin by a spring. As the plunger starts to move upwards the fuel is pushed backwards into the gear pump. 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 drain fuel from the ICV is routed through the ICV pressure regulator and is returned to the tank.24 Valve.3 Liter Engine Fuel System Fuel System . 8.General Information Page 3 The distributor directs the fuel to the correct injector. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . 6. 8. 8.Flow Diagram. 5. 7. 10. 9. Fuel from Supply Tank Electronic Lift Pump Fuel Filter and Water Separator Fuel Drain Line CAPS Injection Pump Distributor Outlet Fitting High Pressure Supply Lines Fuel Connector Injectors Fuel Return to Supply Tank 7-89411NH Section 10 Chapter 12 Issued 8-2001 .3 Liter Engine Fuel System Flow Diagram. 3. 4. 2. Fuel System 1. Fuel System Page 4 24 Valve. ................................................................. 102 mm Hg [4 in Hg] Fuel Drain Line Maximum Pressure........................................................................... 850 to 950 rpm Minimum Lift Pump Inlet Pressure at Rated (vacuum) ............. 102 mm Hg [4 in Hg] Minimum Fuel Filter inlet Pressure during Cranking ...................................................................................................................................................... 102 mm Hg [4 in Hg] Maximum Fuel Filter Outlet Pressure at Rated (vacuum) ..........................................................24 Valve................................................................................................................. 254 mm Hg [10 in Hg] Fuel Inlet Maximum Temperature...............................................................................................................................................................150 rpm 7-89411NH Section 10 Chapter 12 Issued 8-2001 ....................................................................................................... 8...........3 Liter Engine Fuel System Specifications Page 5 Specifications Fuel System Engine Idle Speed .............................................................................. 71°C [160°F] Engine Minimum Cranking Speed ........................................................................... The use of these tools is shown in the appropriate procedure. Tool No. Tool Description CNH299110 Fuel Pump Gear Puller Tool Illustration Used to pull the fuel pump gear. 7-89411NH Section 10 Chapter 12 Issued 8-2001 .Service Tools Page 6 24 Valve.3 Liter Engine Fuel System Service Tools Fuel System The following special tools are recommended to perform procedures in this section. 8. Remove the 2-pin connector from the fuel heater. NOTE: Minimum voltage is 12 volts. A bimetallic strip on the filter head acts as a thermostat. Disconnect the connector from the water-in-fuel (WIF) sensor if equipped. Remove (005-008-002) Disconnect the connector from the fuel heater. The fuel heater will turn on at approximately 1°C [34°F] and turn off at approximately 18°C [65°F]. Check for proper voltage to the fuel heater. Electric (005-008) Page 7 Engine Fuel Heater.3 Liter Engine Fuel System Engine Fuel Heater. If the voltage is not within specifications. refer to the vehicle troubleshooting and repair manual. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Turn the fuel drain valve for approximately 5 seconds to reduce fuel spillage during filter removal. 8. Electric (005-008) Initial Check (005-008-001) NOTE: The fuel heater is not controlled by the electronic control module (ECM).24 Valve. against the filter head. Torque Value: 7-89411NH Section 10 Chapter 12 41 N•m [30 ft-lb] Issued 8-2001 . gasket side facing up. replace the fuel filter. Remove the fuel filter stud. Refer to Procedure 006-015. Install (005-008-026) Install gasket on fuel heater.725 kPa [5 psi]. Install the fuel filter stud.3 Liter Engine Fuel System Remove the fuel filter.Engine Fuel Heater. Remove the fuel heater from the filter head. If the maximum fuel pressure drop across the fuel filter is greater than 0. Apply Loctite® to the filter stud. The heater should be able to be pulled off the filter head. Place the fuel heater. Electric (005-008) Page 8 24 Valve. 8. 3 Liter Engine Fuel System Fuel Flow (005-011) Page 9 Install the fuel filter. Connect fuel heater. Run the engine loaded at rated conditions. Outlet side of the filter should equal 2. Fuel supply restriction should read as follows: Pressure drop across the fuel filter should equal 0.90 kPa [zero to 20 psi].725 kPa [5 psi] maximum. Install two 10 mm [0.24 Valve. 8. 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.96 kPa [10 psi] minimum with the keyswitch in the ON position. 7-89411NH Section 10 Chapter 12 Issued 8-2001 .39 in] Compucheck fittings and a pressure gauge that has a range of at least zero to 2. Refer to Procedure 006-024.725 kPa [5 psi]. replace the fuel filter. Refer to Procedure 006-015. Remove the injection pump upper support bracket. If the restriction is too high. Fuel Pump (005-016) Remove (005-016-002) • • • • • • Disconnect the injection pump supply line. Disconnect the tank return line. 8. Refer to Procedure 006-013. Refer to Procedure 006-020.Fuel Pump (005-016) Page 10 24 Valve. Refer to Procedure 006-051. the supply lines from the fuel supply tank need to be checked. Disconnect the pumping control valve 4-pin Deutsch connector. Disconnect the injection control valve 4-pin Deutsch connector. Remove the injection pump tail support bracket. Remove the injector supply lines. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Disconnect the accumulator pressure/temperature sensor.3 Liter Engine Fuel System If the maximum fuel pressure drop across the fuel filter is greater than 0. Remove the access cap and gear retaining nut and washer. 1 cylinder at TDC. CNH299110. Install (005-016-026) Make sure the engine has No.24 Valve. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Use Tool No.3 Liter Engine Fuel System Fuel Pump (005-016) Page 11 Locate TDC for cylinder No. 1 by barring engine slowly until the line on the pump gear lines up with the line on the gear cover. and pull the fuel injection pump drive gear loose from the pump drive shaft. 8. Remove the fuel injection pump. Remove the four mounting nuts. 3 Liter Engine Fuel System Make sure the fuel injection pump is at its TDC position. The fuel pump drive gear inside diameter and the shaft outside diameter must be clean and dry before installing the gear. 8.Fuel Pump (005-016) Page 12 24 Valve. The fuel injection pump is at No. Torque Value: Fuel Pump Mounting Nuts Fuel Pump Support Brackets 7-89411NH Section 10 Chapter 12 44 N•m [32 ft-lb] 44 N•m [32 ft-lb] Issued 8-2001 . Install the fuel injection pump upper support bracket. Slide the fuel injection pump shaft through the drive gear and position the fuel injection pump flange onto the mounting studs. Install the fuel injection pump tail support bracket. Lubricate the mounting flange with cleaner. Make sure the o-ring seals for the fill orifice (A) and pilot (B) are correctly installed and are not damaged. 1 cylinder TDC when the dowel pin in the shaft (A) is perpendicular to the top of the accumulator. Make sure the dowel pin in the fuel injection pump flange lines up with the hole in the gear housing. Install the mounting nuts. Make sure the dowel pin lines up with the keyway in the fuel injection pump gear. Perform the control valve click test to verify pump is connected to ECM.24 Valve. Refer to Procedure 006-013. • Connect the injection pump supply line. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Torque Value: Fuel Injection Pump 165 N•m [122 ft-lb] Install the gear cover access cap hand tight.3 Liter Engine Fuel System Fuel Pump (005-016) Page 13 30 mm Tighten the fuel injection pump drive gear nut. Refer to Procedure 005-078. • Connect the injection control valve 4-pin Deutsch connector. Refer to Procedure 006024. • Connect the injector supply lines. 8. • Connect the pumping control valve 4-pin Deutsch connector. Operate the engine and check for leaks. Refer to Procedure 006-051. • Connect the tank return line. • Connect the accumulator pressure/temperature sensor connector. Replace the snubber assembly if any parts are damaged. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Dry with compressed air. Inspect for Reuse (005-020-007) Check for broken parts. the seal washers must always be replaced. Always replace the seal washer.3 Liter Engine Fuel System Fuel Pump Delivery Valve (005-020) Preparatory (005-020-000) Thoroughly steam clean the distributor snubber and fuel pump area. the entire snubber assembly must be replaced. Also.Fuel Pump Delivery Valve (005-020) Page 14 24 Valve. The snubber valve and seat are a matched set. 8. Remove the distributor snubber and the seal disk. If either the snubber valve or seat is damaged. Refer to Procedure 006051. or sticking of the snubber valve. do not mix and match valves and seats with other snubber assemblies. debris. Remove (005-020-002) Remove the high pressure fuel supply lines. 3 Liter Engine Fuel System Fuel Pump Delivery Valve (005-020) 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. Refer to Procedure 006-051. Tighten the snubber assemblies.24 Valve. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Torque Value: 81 N•m [60 ft-lb] Install the high pressure fuel supply lines. 8. Install the snubber assembly hand tight. Measure (005-025-010) Measure outlet pressure at the diagnostic fitting on the CAPS pump and compare to the following chart. Engine Speed (rpm) 200 700 1300 2200 Gear Pump Pressure (psi) 2 20 55 120 If pressure is below the minimum values listed and the fuel inlet restriction is satisfactory.3 Liter Engine 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. 8. inspect the gear pump outlet screen. Refer to Procedure 006-020.Fuel Pump Gear Pump (005-025) Page 16 24 Valve. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Fuel Pump Gear Pump (005-025) Preparatory (005-025-000) Perform fuel inlet restriction test. 8. Refer to Procedure 001-031. Refer to Procedure 005-089. Remove the injection pump camshaft nut. 7-89411NH Section 10 Chapter 12 Issued 8-2001 .3 Liter Engine Fuel System Fuel Pump Timing (005-037) Page 17 Recheck gear pump outlet pressure.24 Valve. Operate the engine and check for leaks. the gear pump or the fuel pump gear pump module must be replaced. Fuel Pump Timing (005-037) Remove (005-037-002) Remove the gear cover. If the pressure is still low. and the problem surfaced after gear train removal and replacement.Fuel Pump Timing (005-037) Page 18 24 Valve. Refer to Procedure 001012. determine the cause of misalignment. If this inspection is being performed due to a performance complaint. Install (005-037-026) Install and tighten the injection pump camshaft nut.3 Liter Engine Fuel System Inspect for Reuse (005-037-007) Check that the fuel pump camshaft alignment dowel is present in the fuel pump drive gear keyway. 8. Refer to Procedure 001-031. remove the injection pump. Torque Value: 165 N•m [122 ft-lb] Install the front gear cover. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . If the alignment dowel is not visible. and repair or replace any damaged components. then check the timing of the camshaft gear to the crankshaft gear and the camshaft gear to the fuel pump drive gear. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Do not operate the fuel system with a suction restriction of more than 4 in Hg. check for a good power supply. If the voltage does not meet the specifications. Maximum pressure drop across the filter is 34 kPa [5 psi] or 258 mm Hg [10 in Hg].24 Valve. NOTE: Lift pump runs for only 30 seconds at key ON then shuts off. 8. CAUTION . The fuel lift pump can be cleaned and repaired to a limited extent.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.3 Liter Engine Fuel System Fuel Lift Pump (005-045) 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. 8. NOTE: The 24 Valve. . The pressure drop will increase as the filter removes contamination from the fuel. check for voltage at the lift pump engine harness connector (9 to 12 volts) after keyswitch is on. If the fuel lift pump is not working. water. negative (-) cable first. Disconnect the fuel pump power lead.Fuel Lift Pump (005-045) Page 20 24 Valve. steam. Remove the fuel lift pump inlet and outlet fuel lines. or cleaning solution does not reach inside of the fuel system. 10 mm Remove three capscrews and lift pump from engine block. Refer to Procedure 006-024.3 Liter Engine Fuel System Remove (005-045-002) Disconnect the battery. 8. Test (005-045-012) The output of the fuel lift pump can be checked through the following test. Make sure that the debris. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . NOTE: Thoroughly clean fittings and components before removal. 3 Liter Engine Fuel System Fuel Lift Pump (005-045) Page 21 Test Turn the key switch on. At initial key-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. 8. Install all removed fuel lines. Refer to Procedure 006-024. Install (005-045-026) 10 mm Install the fuel lift pump to block using three capscrews. the lift pump will run for 30 seconds and then stop. Torque Value: 12 N•m [9 ft-lb] Connect the power lead to the fuel lift pump. Valid Pressure mm Hg 508 MIN in Hg 20 Measure the fuel inlet restriction before the fuel lift pump.24 Valve. Measurable restriction is another possible cause for low lift pump pressure. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Refer to Procedure 006-020. check fuel pumpto-engine timing. the distributor module or whole pump will have to be replaced. Inspect for Reuse Check the position of the notch on the rotor. Dry with compressed air. as indicated by misalignment of the rotor. Doing so could cause the rotor to be ejected from the distributor. 8. It should line-up with the alignment mark (A) on the outside of the distributor. the rotor is properly timed to the engine. NOTE: Do not attempt to start the engine with the distributor plug removed. Bar the engine to TDC using the marks on the gear cover and the fuel pump drive gear as a guide. If the alignment is correct. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . CAPS Fuel Injection Pump (005-072) Preparatory (005-072-000) Steam clean the fuel injection pump and the engine in the vicinity of the fuel pump. Pay special attention to the distributor area.Rotor. causing damage to the rotor. Replace if required. Remove the ignition keys from the ignition or otherwise disable the engine starting system. refer to Procedure 005-037 If pump-to-engine timing is okay. If a mechanical problem exists. CAPS Fuel Injection Pump (005-072) Page 22 24 Valve. Remove (005-072-002) Remove the distributor plug (1).3 Liter Engine Fuel System Rotor. Check the o-ring on the distributor plug for damage. With the engine at an idle. Refer to Procedure 005-085. Torque Value: 14 N•m [10 ft-lb] Be sure the rotor is fully engaged before replacing the plug.3 Liter Engine Fuel System Fuel Pump Accumulator (005-077) Page 23 Install (005-072-026) Install the distributor plug and torque. Leak Test (005-072-014) Run the engine and check for fuel leaks. If the accumulator pressure is low. minimum accumulator pressure should be 5000 ± 200 psi. with the keyswitch in the ON position. Fuel Pump Accumulator (005-077) Pressure Test (005-077-013) Using the electronic service tool. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . monitor the accumulator pressure with the engine at idle and under load. Enable the engine starting system. Injection Control Valve (005-078) Click Test (005-078-072) Use an electronic service tool. Under full load the maximum accumulator pressure the pump will develop is 15000 ± 200 psi.24 Valve. 8. to run the Control Valve Click Test. replace the fuel pump accumulator module. with the engine running at idle. An audible click will be heard until none is selected on the Control Valve Click Test screen. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . 8. Cutout Test (005-079-073) The plunger cutout test can be used to check performance of the front and rear pumping plungers. An audible click will be heard until the other pumping control valve is selected. If no click is heard trouble shoot any active fault codes.Pumping Control Valve (005-079) Page 24 24 Valve. Pumping Control Valve (005-079) Click Test (005-079-072) Use an electronic service tool. NOTE: When performing this test the engine load must be the same when each pumping plunger is cutout. Use an electronic service tool. or none is selected on the control valve click test screen. Select the Pumping Control Valve to be tested to initiate the test. to perform this test. Select either front control valve or rear control valve. to run the Control Valve Click Test.3 Liter Engine Fuel System Select Injection Control Valve to initiate the test. If no click is heard troubleshoot any active fault codes. with the keyswitch in the ON position. 24 Valve. refer to procedure 005-088. Select the monitor button and monitor valve close angle (VCA).3 Liter Engine Fuel System Fuel Pump Cam Housing (005-080) Page 25 Select the pumping control valve to be cutout. The VCA should not vary more than 15 degrees crank angle (dca). Cutout the other pumping control valve and record VCA engine speed. Troubleshoot any active fault codes before replacing the accumulator module. Rate Shape (005-081) Preparatory (005-081-000) Thoroughly steam clean the rate shape tube and fuel pump area. Snubber. replace the fuel pump accumulator module. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Replace cam module if necessary. Dry with compressed air. Record VCA. and accumulator pressure after the engine stabilizes. engine speed. Refer to Procedure 005-085. against the results when the front pumping control valve is cutout. If the engine dies when one of the pumping control valves is cutout. 8. and accumulator pressure while the selected plunger is cutout. Fuel Pump Cam Housing (005-080) Inspect for Reuse (005-080-007) Inspect the cam housing for any signs of cracks or fuel leakage. and accumulator pressure after the engine stabilizes. engine speed. Compare the results when the rear pumping control valve is cutout. Leak Test (005-081-014) Run the engine and check for fuel leaks at the rate shape snubber (2) and rate shape tube (4). 1. debris. 8. 3. Remove the rate shape snubber assembly (2). or sticking of the snubber valve. Replace the snubber assembly if any parts are damaged. 2. Rate Shape (005-081) Page 26 24 Valve.3 Liter Engine Fuel System Remove (005-081-002) Remove the rate shape tube (4) assembly. Always replace the seal disk. Inspect for Reuse (005-081-007) Check for broken parts. 6. 5. Snubber Valve Seat Spring Rate Shape Snubber Body Seal Disc Snubber Valve Spring Post.Snubber. 4. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . 8. Apply lube oil to the face of the snubber seat. Install the snubber assembly.24 Valve.3 Liter Engine Fuel System Snubber. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Torque Value: Step 1 Step 2 14 N•m [10 ft-lb] 120 degrees Install the rate shape tube assembly. Rate Shape (005-081) Page 27 Install (005-081-026) Install a new seal disk into the accumulator. This allows the bracket to align with the rate shape tube. Torque Value: 46 N•m [34 ft-lb] NOTE: Make sure that the rate shape tube bracket capscrews are loose. Tighten both rate shape tube nuts. and to the face and threads of the snubber fitting. 8. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Rate Shape (005-081) Page 28 24 Valve. Torque Value: 8.3 Liter Engine Fuel System Verify rate shape tube isolator capscrew torque.5 N•m [75 in-lb] Tighten the rate shape bracket mounting capscrews (1). Torque Value: 41 N•m [30 ft-lb] Operate the engine and check for leaks.Snubber. There are two types of inlet fittings and sealing washers. 8. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . for the type of fitting being removed. 17 mm Remove the distributor inlet fitting. refer to Procedure 005-090. The new design 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.24 Valve. No. Turn the easy out counterclockwise to dislodge the washer.3 Liter Engine Fuel System Fuel Pump Distributor Inlet Fitting (005-084) Page 29 Fuel Pump Distributor Inlet Fitting (005-084) Remove (005-084-002) Remove the rate shape tube assembly. 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. Use the appropriate removal steps below. Use very clean grease to retain the sealing washer to the inlet fitting while it is being installed into the bore. Any dirt trapped in this fitting during assembly will run through the fuel pump and damage the fuel pump. WARNING . WARNING .Fuel Pump Distributor Inlet Fitting (005-084) Page 30 24 Valve. 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. Quite a bit of force is required to remove the sealing washer. Using QD contact cleaner. Clean (005-084-006) . 3824510. Install (005-084-026) . clean the inlet fitting bore from the bottom of the bore outward. Any debris left in this fitting during assembly will run through the fuel pump and damage the fuel pump. 3/16 or 1/8-inch Allen Wrench Old Style Fitting and Washer Pry out the old sealing washer using the modified Allen wrench. Part No. 8.3 Liter Engine 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 installation. Use Lubriplateä 105. or equivalent. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Install sealing washer into counterbore in the inlet fitting. Recheck for fuel leaks or active fault codes.7 N•m [50 in-lb] Rotate 120 degrees clockwise Install the rate shape tube assembly. 8. Torque Value: Step 1 Step 2 5.24 Valve. Start the engine and check for fuel leaks at the rate shape tube connections.3 Liter Engine Fuel System Fuel Pump Distributor Inlet Fitting (005-084) Page 31 17 mm Install new inlet fitting and tighten after sealing washer is seated correctly. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Road-test the vehicle for at least 1 mile. refer to Procedure 005-090. 1 by barring the engine slowly until the line on the pump gear lines up with the line on the gear cover. CAUTION . Remove the air bleed line.Fuel Pump Accumulator Module (005-085) Page 32 24 Valve.3 Liter Engine Fuel System Fuel Pump Accumulator Module (005-085) Preparatory (005-085-000) . 8. or fault codes will possibly occur. Remove (005-085-002) Remove the fuel pump drive gear cover. Remove the rate shape tube assembly. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Locate top dead center for cylinder No. refer to Procedure 005-090. Remove the fuel pump upper support bracket. Thoroughly steam-clean the entire fuel pump. Dry the fuel pump with compressed air. refer to Procedure 006-056. Make sure that steam does not spray directly on the electrical connections on the top of the accumulator block. CAUTION . WARNING . Alternately loosen the capscrew to avoid binding. . The use of air tools will possibly damage the fuel pump.24 Valve. Accumulator module weighs 11 kg [25 lb] and is free to move once the capscrews are removed. Loosen each capscrew about on turn at a time. WARNING . 13 mm Remove two of the four capscrews that are located diagonally from one another. Remove the last two capscrews. Use as much care as possible to avoid dislodging the springs from the bottom of the accumulator. 8. 13 mm . 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Remove accumulator module. Accumulator module weighs 11 kg [25 lb] and is free to move once the capscrews are removed. . Do not use air tools.3 Liter Engine Fuel System Fuel Pump Accumulator Module (005-085) Page 33 Disconnect the 4-pin Deutsch connector for the pumping control valves. Disconnect the 4-pin connector from the fuel pressure/temperature sensor. Reseat springs fully onto plunger barrels.3 Liter Engine Fuel System If the springs are dislodged. to clean the plunger. 3824510. Clean the o-ring groove and mounting surface on the cam housing and the accumulator. The plungers are matched to each bore. NOTE: Before replacing a ceramic plunger. the ceramic plungers can fall out. Use QD contact cleaner. Remove the two o-rings. 3824510. Clean (005-085-006) Clean the small fuel passage using the plastic tube provided with the contact cleaner. Use QD contact cleaner. Wipe out debris with a clean towel. Part No. 8.Fuel Pump Accumulator Module (005-085) Page 34 24 Valve. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Make sure the top of the tappets in the cam housing are clean. and discard them. Do not interchange the plungers. Part No. special care needs to be taken to clean it. Install the accumulator module. Apply Lubriplateä 105. Make sure the tappet assembly is properly aligned. use QD contact cleaner. Fully install the springs on the plunger barrels of the new accumulator module.24 Valve. WARNING . or equivalent. Part No. . remove springs from the old accumulator module. The tappets have a slot on the side that engages a pin on the engine side of the cam housing. 3824510. The ceramic plungers can fall out when removing the plastic caps or old springs. NOTE: Use of two 10 mm x 80 mm studs will aid in the installation. The pin keeps the roller aligned with the camshaft.3 Liter Engine Fuel System Fuel Pump Accumulator Module (005-085) Page 35 Inspect for Reuse (005-085-007) Check the tappets for proper alignment. Install (005-085-026) Install new o-rings. to thoroughly clean the plungers before replacing them. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . 8. If replacing the accumulator module with a new one. If thy fall out. to the o-ring grooves to hold the o-rings in place. Do not interchange the plungers. Use care to avoid dislodging the springs on the accumulator and the o-rings on the cam housing. Torque Value: 44 N•m [32 ft-lb] Install rate shape tube assembly (1). Install the drive gear cover. refer to Procedure 005-090. Install the air bleed line (2). 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Use a mirror if necessary. Recheck for fuel leaks or active fault codes. The use of air tools will possibly damage the fuel pump. Only turn each capscrew about one turn at a time. Draw the accumulator module down evenly. Torque Value: 68 N•m [50 ft-lb] Connect the 4-pin pumping control valve connector. Do not use air tools. refer to Procedure 006-056. Tighten the capscrews.Fuel Pump Accumulator Module (005-085) Page 36 24 Valve. Road-test the vehicle for at least 1 mile. Make sure the o-rings are still in their grooves before the accumulator is fully tightened to the cam housing. 13 mm Install remaining two capscrews. Install the upper support bracket. Start the engine and check for fuel leaks or active fault codes. Install two of the four capscrews. Connect the 4-pin fuel pressure/temperature sensor. CAUTION .3 Liter Engine Fuel System . Tighten the four capscrews. 8. refer to Procedure 006-056. Remove the four capscrews on the distributor. refer to Procedure 005-090. Remove (005-086-002) CAPS vise ring. 8 mm Allen Wrench. CAUTION . The gear pump is free to move after the capscrews are removed. . The capscrews also fasten the gear pump module. Dry the fuel pump with compressed air. Orient the pump with the distributor facing upward to aid in disassembly. or T45 Torx . 3162897 Remove the air bleed line (1). 7-89411NH Section 10 Chapter 12 Issued 8-2001 . CAUTION . or fault codes will possibly occur.24 Valve. Remove the rate shape tube assembly. Remove the fuel pump from the engine.3 Liter Engine Fuel System Fuel Pump Distributor Module (005-086) Page 37 Fuel Pump Distributor Module (005-086) Preparatory (005-086-000) . refer to Procedure 005-016. Thoroughly steam-clean the entire fuel pump. Mount the fuel pump in the vise ring. Loosen but do not remove the distributor plug. 8. Part No. Make sure that steam does not spray directly on the electrical connections on the top of the accumulator block. A polished surface is acceptable. Install (005-086-026) Install the drive coupling. Remove the drive coupling. Clean (005-086-006) Clean the mounting surfaces of the distributor and gear pump. Wear is typically found on the inside corners of the coupling groove. to the coupling to keep it from sliding in the shaft groove during reassembly. Discard the two o-rings. 3824510.Fuel Pump Distributor Module (005-086) Page 38 24 Valve.3 Liter Engine Fuel System Remove the distributor module. Apply Lubricateä 105. Part No. or equivalent. 8. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Inspect for Reuse (00-086-007) Inspect coupling and shaft ends for excessive wear. Center the coupling on the gear pump shaft. Replace coupling if wear is visible. Use QD contact cleaner. The entire distributor module will be ruined and the rotor damage. or equivalent to o-rings to keep them from falling out during reassembly. . Remove the large plug from the end of the distributor. the notch in the rotor will align with the hole in the distributor. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . CAUTION . Make sure the dowel pin is facing up toward the top of the pump. When properly engaged. Do not drop the rotor. The rotor can slide out once the distributor plug is removed. Do not remove the rotor. . Apply Lubriplateä 105. CAUTION . 8. Lightly rotate the rotor with finger-pressure until it drops into the slot in the drive coupling.24 Valve.3 Liter Engine Fuel System Fuel Pump Distributor Module (005-086) Page 39 Install new o-rings. If the shaft needs to be rotated. If the rotor will not engage. install the fuel pump drive nut onto the shaft to provide a means for rotating the shaft. Install the distributor module. remove the distributor. and reposition the drive coupling in the center of the shaft. remove the distributor housing. The rotor must be properly timed to the fuel pump camshaft. 8.Fuel Pump Distributor Module (005-086) Page 40 24 Valve.3 Liter Engine Fuel System . T45 Torx Make sure the o-rings are not pinched. Tighten the distributor plug. Install the fuel pump on the engine. Torque Value: 48 N•m [35 ft-lb] 8 mm Allen Wrench Install a new o-ring on the distributor plug. refer to Procedure 006-056. Install the four distributor capscrews. refer to Procedure 005-090. Tighten the capscrews. Install the large plug at the end of the distributor. and repeat the previous step. refer to Procedure 005-016. Torque Value: 14 N•m [120 in-lb] Install the rate shape tube assembly. Make sure the fuel pump camshaft dowel pin is pointing toward the top of the pump before reinstalling. CAUTION . If not properly timed. Install the air bleed line (1). Improper assembly will cause the rotor to be 180 degrees out of time. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . 24 Valve. 8. Road-test the vehicle for at least 1 mile. Recheck for fuel leaks or active fault codes.3 Liter Engine Fuel System Fuel Pump Distributor Module (005-086) Page 41 Run the injection control valve click test using INSITEä. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . refer to Procedure 005-078. Start the engine and check for fuel leaks or active fault codes. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Refer to the procedure for the fuel pump removal and installation. 8. Procedure 005-086.Fuel Pump Injection Control Valve (005-087) Page 42 24 Valve. The distributor and injection control valve modules must be replaced together.3 Liter Engine Fuel System Fuel Pump Injection Control Valve (005-087) This module is not able to be replaced as a separate unit at this time. refer to Procedure 005-089. Thoroughly steam-clean the entire fuel pump. 8. Mount the fuel pump in the vise ring. Make sure the roller rotates freely and smoothly. Inspect for Reuse (005-088-007) Remove the roller tappets from the cam housing bores. Replace the cam housing module if the rollers are worn. refer to Procedure 005-016.24 Valve. Remove the fuel pump from the engine. CAUTION . refer to Procedure 006-056. Inspect the roller surfaces for pitting and wear. Dry the pump with compressed air. Remove the rate shape tube assembly. or fault codes will possibly occur. Orient the pump with the distributor facing upward to aid in disassembly. Remove the gear pump module. Remove (005-088-002) Remove the air bleed line (1). Make sure that steam does not spray directly on the electrical connections on the top of the accumulator block. Remove the accumulator module.3 Liter Engine Fuel System Fuel Pump Cam Housing Module (005-088) Page 43 Fuel Pump Cam Housing Module (005-088) Preparatory (005-088-000) . 7-89411NH Section 10 Chapter 12 Issued 8-2001 . refer to Procedure 005-090. refer to Procedure 005-085. refer to Procedure 005-086. Remove the distributor module. The bearings must turn smoothly and free during rotation.3 Liter Engine Fuel System Inspect the camshaft lobes for pitting and wear. Using fingers. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Inspect the tappet bores for scuffing or wear to the housing. Clean (005-088-006) Clean the mounting surfaces of the cam housing. make sure the camshaft turns freely. 3824510. Part No. Polishing will occur in vertical bands at many places around the inside of the bores. Check the camshaft for end play.002 in] of end play.Fuel Pump Cam Housing Module (005-088) Page 44 24 Valve. Polish of the bores is acceptable. or damage to the guide pins. Replace the cam housing if there is any scuffing or wear on the bores. If any end play can be felt. Replace the cam housing if the bearings are tight or rough. Use QD contact cleaner. replace the cam housing assembly.05 mm [0. If there is more than 0. Replace the cam housing if there is any pitting or wear. use a dial indicator to check it. 8. The ceramic plungers will possibly fall out when removing the springs. If the plungers fall out. 3824510. Check the tappets for proper alignment. Part No. to thoroughly clean them before replacing. Install the fuel pump onto the engine. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Make sure the tappet is properly aligned. The tappets have a slot on the side that engages a pin on the engine side of the cam housing. Install the air bleed line.3 Liter Engine Fuel System Fuel Pump Cam Housing Module (005-088) Page 45 Install (005-088-026) Make sure the timing dowel pin in the camshaft points toward the top of the fuel pump. refer to Procedure 005-056. 8. Install the gear pump module. refer to Procedure 005-089. refer to Procedure 005-016. refer to Procedure 005-086. refer to Procedure 005-085.24 Valve. . Lubricate the tappets and camshaft lobes with clean 15W-40 engine oil. Install the accumulator module. The pin keeps the roller aligned with the camshaft. refer to Procedure 005-090. Do not interchange the plungers. WARNING . Install the roller tappets into the cam housing. Install the distributor module. Install the new springs onto the plunger barrels of the accumulator module. Install the rate shape tube assembly. use QD contact cleaner. Road-test the vehicle for at least 1 mile. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . Recheck for fuel leaks and active fault codes.Fuel Pump Cam Housing Module (005-088) Page 46 24 Valve.3 Liter Engine Fuel System Start the engine and check for fuel leaks or active fault codes. 8. Remove the distributor module. Remove the rate shape tube. Remove the gear pump module. refer to Procedure 005-086. or fault codes will possibly occur. Remove the fuel pump from the engine. 7-89411NH Section 10 Chapter 12 Issued 8-2001 .24 Valve. Thoroughly steam-clean the entire fuel pump. Make sure that steam does not spray directly on the electrical connections on the top of the accumulator block. Replace the coupling if wear is visible.3 Liter Engine Fuel System Fuel Pump Gear Pump Module (005-089) Page 47 Fuel Pump Gear Pump Module (005-089) Preparatory (005-089-000) . Remove (005-089-002) Remove the air bleed line (1). NOTE: Do not remove the two capscrews. refer to Procedure 005-090. refer to Procedure 005-016. A polished surface is acceptable. The gear pump will slide off of the dowel pins once the distributor is removed. 8. Mount the fuel pump in the vise ring. Dry the fuel pump with compressed air. Inspect for Reuse (005-089-007) Inspect the drive coupling and shaft ends for excessive wear. CAUTION . Orient the pump with the distributor facing upward to aid in disassembly. refer to Procedure 006-056. Install (005-089-026) . 7-89411NH Section 10 Chapter 12 Issued 8-2001 . or equivalent. CAUTION . The longer o-ring goes to the side facing the cam housing.3 Liter Engine Fuel System Clean (005-089-006) Clean the mounting surfaces of the gear pump and cam housing. Center the coupling in the shaft. Install new o-rings. 8. Align the gear pump shaft with the drive coupling. to the o-rings to keep them from falling out during assembly. Part No. The larger o-rings on either end of the gear pump differ in size. Use QD contact cleaner. Apply Lubricateä 105. Install the drive coupling.Fuel Pump Gear Pump Module (005-089) Page 48 24 Valve. 3824510. refer to Procedure 005-016. refer to Procedure 005-090. Install the fuel pump on the engine. Recheck for fuel leaks or active fault codes. refer to Procedure 006-056. Make sure the timing dowel pin is facing toward the top of the fuel pump.3 Liter Engine Fuel System Fuel Pump Gear Pump Module (005-089) Page 49 Install the gear pump module.24 Valve. 8. refer to Procedure 005-086. Install the distributor module. Road-test the vehicle for at least 1 mile. Install the rate shape tube. Install the air bleed line (1). Make sure the o-rings are not pinched. Start the engine and check for fuel leaks or active fault codes. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . fault codes will possibly occur. Clean (005-090-006) Clean the ends of the rate shape tube. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . 3824510.Fuel Pump Rate Shape Tube (005-090) Page 50 24 Valve. Dry the fuel pump with compressed air Remove (005-090-002) 10 mm. 8. Make sure that direct steam spray stream does not contact the electrical connections on the top of the accumulator block. or missing. Clean out the rate shape tube with contact cleaner if debris is suspected of entering the tube.3 Liter Engine Fuel System Fuel Pump Rate Shape Tube (005-090) Preparatory (005-090-000) . Remove the rate shape tube assembly. CAUTION . cracked. Inspect the ends of the rate shape tube for damage. Do not loosen or remove the isolator capscrews (3). Inspect for Reuse (005-090-007) Inspect isolators for signs of wear or cracks. Replace rate shape tube assembly if any isolator is worn. Remove the two bracket capscrews (2). 19 mm Loosen the two rate shape tube nuts (1).. Thoroughly steam-clean the entire fuel pump. Part no. Flush any dirt from the snubber fitting and distributor inlet fitting. Use QD contact cleaner. Torque Value: 41 N•m [30 ft-lb] NOTE: Isolator capscrew torque is 12 N•m [110 in-lb] if loosened. 7-89411NH Section 10 Chapter 12 Issued 8-2001 . 8. 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. Tighten the bracket capscrews (2). 8 mm. 19 mm Install the rate shape tube assembly using the following steps: Tighten the rate shape tube nuts (1).3 Liter Engine Fuel System Fuel Pump Rate Shape Tube (005-090) Page 51 Install (005-090-026) 8 mm.24 Valve. the rate shape tube must be replaced with a new tube. Start the engine and check for fuel leaks at the rate shape tube connections. 10 mm Install the two bracket capscrews. Template Name: IS_2_col Template Date: 2000_01_13_v5.6 .5.