Home » ISX11.9 CM2250 - Service Manual » Cummins ISX11.9 CM2250 – Service Manual 005-226   Fuel Pump Head Outlet Fitting

Cummins ISX11.9 CM2250 – Service Manual 005-226   Fuel Pump Head Outlet Fitting

Preparatory Steps

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 WARNING 

When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury.
 WARNING 

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

Clean all fittings before disassembly. Dirt or contaminants can damage the fuel system.

Before servicing any fuel system components, (such as fuel lines, fuel pump, injectors, etc.) which would expose the fuel system, or internal engine components, to potential contaminants prior to disassembly, clean the fittings, mounting hardware, and the area around the component to be removed. Dirt or contaminants can be introduced into the fuel system and engine, if the surrounding areas are not cleaned, resulting in damage to the fuel system and engine.

Thoroughly clean the entire fuel pump. Dry with compressed air.

To prevent engine damage from debris or contamination, cover, cap, or plug any openings as soon as possible when servicing the fuel system. Caps and plugs can be found in Clean Care Kit Part Number 4919073.

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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 cable last.
  • Disconnect the batteries. Rever to the OEM service manual.

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 WARNING 

Normal engine operation creates highly pressurized fuel in the fuel line which will remain in the fuel line after engine shutdown. Never open the fuel system when the engine is operating. Before servicing the fuel system, always loosen the pump to rail fuel line at the rail to vent the pressure. Keep hands clear of the line when loosening. High pressure fuel spray can penetrate the skin, resulting in serious personal injury or death.

Before servicing the fuel system, loosen the pump to rail line at the rail to vent the pressure.

Keep hands clear of the line when loosening.

NOTE: A machined slot in this fitting directs the fuel spray toward the inboard side of the fuel rail.

Remove the high-pressure pump to rail fuel line from the fuel pump head. Refer to Procedure 006-051 in Section 6. The fuel pump head outlet fitting sealing washer must be replaced if the fuel pump head outlet fitting is removed.

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Remove

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Remove the flat washer. The flat sealing washer is swaged into the inlet fitting bore during installation.

A special tool can be created to aid in its removal by grinding the short leg of a 1/8-inch or 3/16-inch Allen wrench, so the wrench is no longer than 13-mm [1/2-in] long when measured from the outside of the long leg.

This tool acts as a mini heel-bar to pry out the sealing washer without damaging the back of the hole.

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Remove the fuel pump head outlet fitting.

The fuel pump head outlet fitting sealing washer must be replaced if the fuel pump head outlet fitting is removed.

Pry out the old sealing washer from the threaded hole in the back of the high-pressure pump head using the modified Allen wrench.

NOTE: Considerable force is required to remove the sealing washer.

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Clean and Inspect for Reuse

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Clean the threaded hole in the high-pressure pump head with contact cleaner, Part Number 3824510 or equivalent.

Inspect the threads and cavity in the high-pressure pump head for burrs or debris.

Inspect the seal washer end of the outlet fitting. There should be a polished crown that is free of nicks or inclusions. If the crown is damaged or severely flattened, the outlet fitting must be replaced.

Clean any burrs with a wire brush, then flush the bore clean with contact cleaner.

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Install

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NOTE: This joint is designed to seal in excess of 240,000 kPa [34,800 psi]. Seal washers must not be reused.

Install a new seal washer onto the outlet fitting. The seal washer should pilot into the outlet fitting. A small amount of clean grease, such as assembly lubricant, will help in keeping the seal attached to the outlet fitting during installation.

Tighten the fuel pump outlet fitting.

Torque Value:

  1. 13.6 n.m   
    [120 in-lb]
  2. Rotate 90 degrees

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Finishing Steps

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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 cable last.
  • Install the pump to rail injector supply line to the fuel pump head. Refer to Procedure 006-051 in Section 6.
  • Connect the batteries. Refer to the OEM service manual.
  • Operate the engine and check for leaks.

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Last Modified:  27-May-2010