Section 10 Chapter 13

Section 10 Chapter 13 24 Valve, 8.3 Liter Engine Injectors and Fuel Lines Note: All coding used in the 8.3 Liter and 9 Liter engine manuals are Cumm...
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Section 10 Chapter 13

24 Valve, 8.3 Liter Engine Injectors and Fuel Lines

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.

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24 Valve, 8.3 Liter Engine Injectors and Fuel Lines

Page a

Injectors and Fuel Lines Contents Air in Fuel (006-003)....................................................................................................................................................................................... 3 Measure (006-003-010) ................................................................................................................................................................... 3 Test (006-003-012) .......................................................................................................................................................................... 3 Fuel Connector (Head Mounted) (006-052) ................................................................................................................................................ 22 Inspect for Reuse (006-051-007) ................................................................................................................................................... 22 Install (006-052-026) ...................................................................................................................................................................... 22 Remove (006-052-002) .................................................................................................................................................................. 22 Fuel Drain Line Restriction (006-012) ........................................................................................................................................................... 5 Measure (006-012) ........................................................................................................................................................................... 5 Fuel Drain Lines (006-013) ............................................................................................................................................................................ 6 Remove (006-013-002) .................................................................................................................................................................... 6 Initial Check (006-013-001) .............................................................................................................................................................. 6 Inspect for Reuse (006-013-007) ..................................................................................................................................................... 7 Install (006-013-026) ........................................................................................................................................................................ 7 Fuel Filter (Spin-On Type) (006-015) ............................................................................................................................................................ 8 Remove (006-015-002) .................................................................................................................................................................... 8 Install (006-015-026) ........................................................................................................................................................................ 8 Fuel Filter Head Bracket (006-018) ............................................................................................................................................................. 10 Assemble (006-018-025) ................................................................................................................................................................ 11 Disassemble (006-018-003) ........................................................................................................................................................... 10 Inspect for Reuse (006-018-007) ................................................................................................................................................... 11 Install (006-018-026) ...................................................................................................................................................................... 11 Remove (006-018-002) .................................................................................................................................................................. 10 Fuel Inlet Restriction (006-020) ................................................................................................................................................................... 12 Initial Check (006-024-001) ............................................................................................................................................................ 12 Fuel Pump Air Bleed Line (006-056)............................................................................................................................................................ 23 Remove (006-056-002) ................................................................................................................................................................... 23 Install (006-056-026) ....................................................................................................................................................................... 24 Fuel Supply Lines (006-024) ........................................................................................................................................................................ 12 Initial Check (006-024-001) ............................................................................................................................................................ 12 Inspect for Reuse (006-024-007) ................................................................................................................................................... 13 Install (006-024-026) ...................................................................................................................................................................... 13 Remove (006-024-002) .................................................................................................................................................................. 13

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Section 10 Chapter 13

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24 Valve, 8.3 Liter Engine Injectors and Fuel Lines

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Injector (006-026) ......................................................................................................................................................................................... 13 Assemble (006-026-025) ............................................................................................................................................................... 17 Clean (006-026-006) ...................................................................................................................................................................... 15 Disassemble (006-026-003) ........................................................................................................................................................... 14 Inspect (006-026-062) .................................................................................................................................................................... 17 Inspect for Reuse (006-026-007) ................................................................................................................................................... 15 Install (006-026-026) ...................................................................................................................................................................... 18 Measure (006-026-010) ................................................................................................................................................................. 15 Remove (006-026-002) .................................................................................................................................................................. 13 Test (006-026-012) ........................................................................................................................................................................ 15 Injectors and Fuel Lines - General Information .......................................................................................................................................... 1 General Information ......................................................................................................................................................................... 1 Injector Supply Lines (High Pressure) (006-051) ...................................................................................................................................... 19 Initial Check (006-051-001) ............................................................................................................................................................ 19 Inspect for Reuse (006-051-007) ................................................................................................................................................... 20 Install (006-051-026) ...................................................................................................................................................................... 21 Remove (006-051-002) .................................................................................................................................................................. 20

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Section 10 Chapter 13

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24 Valve, 8.3 Liter Engine Injectors and Fuel Lines

Injectors and Fuel Lines - General Information Page 1

Injectors and Fuel Lines - General Information General Information , WARNING , Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area and areas sharing ventilation to avoid severe personal injury or death when working on the fuel system. Injectors used in the 24 Valve, 8.3 Liter engines have hole type nozzles. High pressure fuel flows into the side of the injector and causes the needle to lift and fuel to be injected. The clearances in the nozzle bore are extremely small and any sort of dirt or contaminants will cause the injector needle valve to stick. This is why it is important to clean around any fuel connection before servicing it. Also, cap or cover any open fuel connections before a fuel system repair is performed. High pressure fuel is supplied to the injector (1) from the fuel pump via an injector supply line (2) and a fuel connector (3). The end ferrule on the injector supply line pushes against the fuel connector when the fuel line nut is torqued in the cylinder head. This force provides the sealing pressure between both the injector supply line to the fuel connector and the connector to the injector. The torque on this line is critical. If the nut is under torqued, the surfaces will not seal and a high pressure fuel leak will result. If the nut is over torqued, the connector and injector will deform and also cause a high pressure leak. The leak may result in an injector misfire and low power. Always lubricate the threads of the high pressure line nuts with engine oil before tightening. Always make sure the proper torque is used on the high pressure line nuts. The fuel connector contains an edge filter that breaks up small contaminants that enter the fuel system. The edge filter uses the pulsating high pressure to break up most particles so they are small enough to pass through the injector. NOTE: The edge filters are not a substitute for cleaning and covering all fuel system connections during repair. Edge filters are not a substitute for maintaining the recommended engine mounted fuel filter.

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24 Valve, 8.3 Liter Engine Page 2

Injectors and Fuel Lines - General Information Injectors and Fuel Lines

The fuel filter is a spin-on type. Fuel flows around the outside of the filter and back up through the middle. The filtering media is a 10 micron Stratapore design for efficient debris removal. The filter also strips the water and collects it at the bottom of the filter to be drained daily.

The 24 Valve, 8.3 Liter Engine lift pump will run for approximately 30 seconds after the key is switched on to assist with fuel priming. The lift pump will run during cranking and while the engine is running until the 30 seconds has lapsed. The lift pump will shut off anytime the key is switched off. The 30 second timer is reset after each key switch cycle and ECM power down.

Once the engine is started, additional fuel is drawn through the lift pump head via the gear pump. A valve in the head opens when the gear pump requires more flow than the lift pump can provide or when the lift pump is shut off.

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24 Valve, 8.3 Liter Engine Injectors and Fuel Lines

Air in Fuel (006-003) Page 3

Air in Fuel (006-003) Measure (006-003-010) , CAUTION , The pressure of the fuel line is sufficient to penetrate the skin and cause serious bodily harm. To check for air in the high pressure lines, loosen the fittings at the head. Crank the engine to allow entrapped air to bleed from the line. Tighten the fittings. Torque Value:

37 N•m

[28 ft-lb]

High pressure line tube nuts should be lubricated with fuel or oil before torquing.

, CAUTION , Do not bleed a hot engine as this could cause fuel to spill onto the hot exhaust manifold creating a danger of fire. Operate the engine and vent one line at a time until the engine runs smoothly.

Test (006-003-012) The air bleed fitting on the CAPS fuel system creates a self-bleeding system during replacement of the supply side components. High pressure fuel line removal and replacement will not require external bleeding to start the engine. The CAPS fuel pump will create high fuel pressure during cranking and purge the air in the high pressure side through the injectors. Generally, most of the air that enters the low pressure system during component replacement can be bled out by turning the fuel lift pump on for 30 seconds. NOTE: To run the fuel lift pump for an additional 30 seconds, cycle the key switch to off, pause for 30 seconds then turn the key switch to the ON position.

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Air in Fuel (006-003) Injectors and Fuel Lines

NOTE: If an excessive amount of air has entered the system, the system will need to be bled. Loosen the fuel supply line at the CAPS pump. Run the fuel lift pump until the air has been bled. When all the air has been bled, retighten the fitting.

If air continues to appear in the system for several minutes, an air leak is present. A source, which is often overlooked, for air to enter the fuel system is between the inlet of the pre-filter and the suction tube in the tank. Fuel tanks that have the outlet fitting at the top will have a suction tube at the bottom of the tank. Cracks or pin holes in the weld that joins the tube to the fitting can let air enter the fuel system. Check to make sure that all fittings from the fuel supply line on the tank to the inlet of the fuel lift pump are tight.

Supply line leaks from the lift pump to the CAPS fuel pump may be located by operating the lift pump via an electronic service tool or key switch cycling, to build pressure in the fuel lines. Inspect all lines, connections, and filter assembly for an external fuel leak.

19 mm A stuck open injector can also blow combustion gas back into the pump and cause air to be present in the overflow. If the engine seems to be misfiring or running rough, break all the injector supply lines loose at the pump end. Crank the engine and observe the lines. If combustion gas seems to be blowing back through the line, the injector is stuck open. Remove and test the injector, refer to Procedure 006-026. Torque Value:

24 N•m

[18 ft-lb]

NOTE: Use two wrenches when loosening the lines at the fuel pump, one to hold the delivery valve and one to loosen the line.

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24 Valve, 8.3 Liter Engine Injectors and Fuel Lines

Fuel Drain Line Restriction (006-012) Page 5

Fuel Drain Line Restriction (006-012) Measure (006-012) Remove the fuel drain line from the fitting at the rear of the lift pump head. Install a test fitting. Install the zero to 762 mm Hg [zero to 30 in Hg] pressure gauge.

Operate the engine at rated speed and no load.

Observe the reading on the gauge. Fuel Drain Line Pressure mm Hg 254.0

MAX

in Hg 10.0

If the drain line pressure is out of specification, check for bends or kinks in the drain lines or plugged fuel tank vent valves.

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Fuel Drain Lines (006-013) Injectors and Fuel Lines

Fuel Drain Lines (006-013) Initial Check (006-013-001) Inspect the drain lines for any signs of leaks, cracks, chafing, loose, or broken brackets.

Remove (006-013-002) 10 mm Remove the capscrew from the fuel line brace. Clean all fittings before disassembly. Dirt or contaminants can damage the fuel system.

19 mm, 15 mm Remove the banjo fitting at the fuel pump return line. Use two wrenches to prevent the fuel line from being bent. Remove drain line fittings at CAPS pump.

17 mm Remove drain line from the banjo connection at the rear of the head.

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Fuel Drain Lines (006-013) Page 7

17 mm, 19 mm Disconnect the drain lines from the lift pump.

Inspect for Reuse (006-013-007) Inspect lines for clogging or a damaged connector.

Install (006-013-026) 19 mm, 15 mm Connect fuel drain line at fuel pump banjo, rear fitting at the cylinder head, and lift pump. Use two wrenches when installing the drain line at the fuel pump return. Use new sealing washers at pump banjo. Torque Value:

24 N•m

[18 ft-lb]

10 mm Install and tighten the clamp capscrews. Torque Value:

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24 N•m

[18 ft-lb]

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24 Valve, 8.3 Liter Engine Page 8

Fuel Filter (Spin-On Type) (006-015) Injectors and Fuel Lines

Run the engine under a load and check for leaks.

Fuel Filter (Spin-On Type) (006-015) Remove (006-015-002) 80 to 95 mm, Filter Wrench Disconnect wiring harness from WIF, if equipped. Disconnect wiring harness from fuel heater (if equipped). Loosen the combination water separator/fuel filter.

Remove the combination water separator/fuel filter. NOTE: Make sure o-ring does not stick to filter head. Remove o-ring with screwdriver if necessary.

Install (006-015-026) Install the water-in-fuel (WIF) sensor into the new fuel filter, if necessary.

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Fuel Filter (Spin-On Type) (006-015) Page 9

The 24 Valve, 8.3 Liter Engine has a self-priming, low-pressure system that purges the air from the fuel system. There is no need to pre-fill the new filter with fuel, but it is recommended. Lubricate the o-ring with clean lubricating oil.

, CAUTION , Mechanical tightening may distort the threads as well as damage the filter element seal or filter canister. Install the filter as specified by the filter manufacturer.

Connect the water-in-fuel (WIF) sensor to the wiring harness (if equipped). Connect the wiring harness to the heater (if equipped).

Turn the key to the ON position, but do not attempt to start the engine for 30 seconds. The electric fuel transfer pump will run and purge air from the system for about 30 seconds. After 30 seconds attempt to start the engine. Operate the engine and check for leaks.

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Fuel Filter Head Bracket (006-018) Injectors and Fuel Lines

Fuel Filter Head Bracket (006-018) Remove (006-018-002) Remove the fuel filter. Refer to Procedure 006-015.

1 Inch Remove the fuel supply lines from the filter head.

13 mm, 9/16-Inch Remove the four capscrews retaining the filter head. Remove the filter head bracket from the engine bracket.

Disassemble (006-018-003) Remove the fuel heater (if equipped). Remove the filter adapter stud.

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24 Valve, 8.3 Liter Engine Injectors and Fuel Lines

Fuel Filter Head Bracket (006-018) Page 11

Inspect for Reuse (006-018-007) Inspect the filter head for cracks, passage blockage, material or debris on the sealing surfaces.

Assemble (006-018-025) 7/8-Inch Apply Loctite™ 277, or equivalent, to the filter adapter threads that are engaging the filter head. Assemble the filter head. Install the filter adapter and fuel heater (if equipped). Torque Value:

3.4 N•m

[30 in-lb]

NOTE: Make sure there is an o-ring between the filter head and heater.

Install (006-018-026) 14 mm, 9/16-Inch Install the bracket and filter head. Tighten the retaining capscrews. Torque Value:

43 N•m

[32 ft-lb]

37 N•m

[27 ft-lb]

1 Inch Install fuel lines. Torque Value:

Install the fuel filter. Refer to Procedure 006-015.

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24 Valve, 8.3 Liter Engine Page 12

Fuel Inlet Restriction (006-020) Injectors and Fuel Lines

Run the engine and check for leaks.

Fuel Inlet Restriction (006-020) Initial Check (006-024-001) Install a fitting at the lift pump inlet. Install a vacuum gauge that has a range of at least zero to 508 mm Hg [zero to 20 in Hg]. Measure the inlet restriction. Fuel Inlet Restriction mm Hg 8

MAX

in Hg 4

If the fuel inlet restriction is too high, check to make sure the lines from the tank are sized properly, there are no kinks or bends in the lines, and the lines are not clogged. Also, make sure there are no clogged fuel strainers or malfunctioning check valves.

Fuel Supply Lines (006-024) Initial Check (006-024-001) Inspect all fuel supply line fittings and lines. Look for cracks in the lines or leaking fitting.

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24 Valve, 8.3 Liter Engine Injectors and Fuel Lines

Injector (006-026) Page 13

Remove (006-024-002) 1 Inch Remove fuel supply lines.

Inspect for Reuse (006-024-007) Look for burrs or debris around the fittings that could cause a leak, also look for damaged or frayed flexible fuel hose.

Install (006-024-026) 1 inch Install fuel supply lines. Torque Value:

37 N•m

[27 ft-lb]

Injector (006-026) Remove (006-026-002) Remove the rocker lever cover. Refer to Procedure 003-011. Remove the injector supply lines. Refer to Procedure 006-051. The fuel connector must be removed before removing the injector or damage to the connector will result.

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Injector (006-026) Injectors and Fuel Lines

8 mm Remove the injector hold-down.

Injector Puller, Tool No. 3825156 Using the injector puller, Tool No. 3825156, pull the injector out of the head.

Disassemble (006-026-003) Place the injector in the injector clamp and remove the nozzle retaining nut. NOTE: Injectors covered under warranty by the manufacturer should not be repaired. Refer to the manufacturer's warranty instructions.

Remove the nozzle, intermediate plate, spring, and shims from the injector.

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Injector (006-026) Page 15

Clean (006-026-006) , WARNING , Do not use a steel wire brush or glass beading to clean the injectors. This will damage the nozzle holes and cause performance problems. Clean injector tip and body with safety solvent and soft clean rag. If necessary use a brass brush to clean off carbon.

Inspect for Reuse (006-026-007) Inspect the injector. Inspect o-ring for damage. Look for burrs on the inlet to the injector. Check the nozzle holes for any signs of damage such as hole erosion or hole plugging. Also check the nozzle color for signs of overheating. Overheating will cause the nozzle to turn dark yellow/ tan or blue color depending on the temperature of overheat.

Measure (006-026-010) Verify the injector sealing washer is the correct thickness. The incorrect sealing washer can cause high pressure fuel leaks, and/or performance problems due to incorrect injector protrusion. Refer to the injector part number for correct sealing washer shim thickness. NOTE: All 1998 emissions engines use 1.5 mm [0.06 in] injector shims.

Test (006-026-012) Injector Nozzle Tester, Tool No. 3162269 Install the injectors on an injector test stand. Open the bypass valve for the pressure gauge so the spray pattern can be checked.

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Injector (006-026) Injectors and Fuel Lines

Operate the test stand lever quickly several times to check the spray pattern of the injectors. Verify that the correct number of plumes are present for the number of holes in the injector. Also pay close attention to the size and shape of each plume. If possible, compare the spray pattern to that of a new injector with the same assembly number. NOTE: The injector spray pattern is an excellent indicator of the nozzle hole condition. Check each plume carefully because it is possible that only a single hole has been damaged, yet significant performance issues may result.

Close the bypass valve for the pressure gauge and operate the test stand lever to check the nozzle opening pressure. There should be a good crisp pop when the nozzle opens and the pressure should be within specification for the assembly number.

If the nozzle opening pressure is excessively low and/or the nozzle sprays excessive fuel, the injector needle may be sticking. The needle may be stuck due to poor lubrication or debris. Sometimes it is possible to unstick an injector needle by using the injector test stand. Open the bypass valve for the pressure gauge and operate the test stand lever rapidly for 10 to 20 strokes.

Recheck the nozzle opening pressure and spray pattern to see if the injector has returned to normal operation. If the injector is still out of specification, replace the injector.

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Section 10 Chapter 13

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24 Valve, 8.3 Liter Engine Injectors and Fuel Lines

Injector (006-026) Page 17

Check the injector for drip and/or excessive leak down. Close the bypass valve for the pressure gauge and build pressure to within 10 bars of the opening pressure of the nozzle. A drop of fuel should not form within 15 seconds.

Inspect (006-026-062) Remove the needle from the nozzle tip and inspect the color. Look for signs of excessive carbon or overheating (dark yellow/tan or blue color of needle). Also look for scuffing marks on the needle. NOTE: Do not touch needle with finger tips. Oil from fingers will damage the needle. Hold the needle by the stem. If needle is touched wipe clean with soft cloth and dip in diesel fuel.

Dip the needle in clean diesel fuel and insert the nozzle. Hold the nozzle at a 45 degree angle and pull the needle 2/3 the way out. Under its own weight the needle should slide smoothly back onto the nozzle.

Assemble (006-026-025) Clean injector internal components with clean diesel fuel and clean rag. Make sure there is no debris in the internal parts of the injector.

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Injector (006-026) Injectors and Fuel Lines

Install shims necessary to modify the nozzle opening pressure. More shims raise the nozzle opening pressure, less shims lower the nozzle opening pressure.

Install the spring, button, intermediate plate, and nozzle/needle. Make sure that the intermediate plate is in the correct orientation with the supply hole on the plate lining up with the supply hole on the holder.

Install the retaining nut finger tight. Place the injector in the injector clamp and tighten the retaining nut. Install the sealing washer and body o-ring. Torque Value:

47 N•m

[35 ft-lb]

Install (006-026-026) 8 mm Place the injector in the head in the proper orientation. Install the injector hold-down and tighten. Torque Value:

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Section 10 Chapter 13

10 N•m

[89 in-lb]

Issued 8-2001

24 Valve, 8.3 Liter Engine Injectors and Fuel Lines

Injector Supply Lines (High Pressure) (006-051) Page 19

Install the fuel connector. Refer to Procedure 006-052. Install the rocker lever cover. Refer to Procedure 003-011. Install the high pressure fuel lines. Refer to Procedure 006-051.

Operate the engine and check for leaks.

Injector Supply Lines (High Pressure) (006051) Initial Check (006-051-001) 17 mm, 19 mm Inspect the lines for cracks, chafing, or leaks. Make sure that the lines are tightened to the proper specification. 17 mm Check the fuel pump connection. Torque Value:

24 N•m

[18 ft-lb]

19 mm Check the cylinder head connection. Torque Value:

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38 N•m

[28 ft-lb]

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24 Valve, 8.3 Liter Engine Page 20

Injector Supply Lines (High Pressure) (006-051) Injectors and Fuel Lines

Remove (006-051-002) 19 mm, 17 mm Remove the fuel line from the injection pump. NOTE: Use two wrenches to prevent the outlet fitting from turning.

10 mm Remove the fuel line clamp capscrews from the intake cover. Fuel line clamp capscrews must be removed from the intake cover before injection line can be pulled loose from head.

19 mm Remove the fuel line from the cylinder head. NOTE: Use two wrenches to prevent the outlet fitting from turning.

Inspect for Reuse (006-051-007) Check the ferrules of the lines for any signs of burrs or foreign material. Check for cracks and deformation.

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Section 10 Chapter 13

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24 Valve, 8.3 Liter Engine Injectors and Fuel Lines

Injector Supply Lines (High Pressure) (006-051) Page 21

Install (006-051-026) Before installing the injector supply lines, make sure that the fuel connector is fully and properly seated against the injector.

19 mm, 17 mm Install the fuel lines in the reverse order of removal. 17 mm Check the fuel pump connection. Torque Value:

24 N•m

[18 ft-lb]

19 mm Check the cylinder head connection. Torque Value:

38 N•m

[28 ft-lb]

, WARNING , Do not bleed a hot engine as this could cause fuel to spill onto a hot exhaust manifold creating a danger of fire. Operate the engine and vent one line at a time until the engine runs smoothly.

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Fuel Connector (Head Mounted) (006-052) Injectors and Fuel Lines

Fuel Connector (Head Mounted) (006-052) Remove (006-052-002) Fuel Connector Puller, Tool No. 3825157 Remove injector supply line. Refer to Procedure 006-051. Install a fuel connector puller, Part No. 3825157. Remove the fuel connector out of the cylinder head. NOTE: When removing the fuel connector from the cylinder head, care must be taken to make sure that the connector o-ring is not damaged.

Inspect for Reuse (006-051-007) Inspect the fuel connector. Look for burrs or deformation around the inlet and outlet sides of the connector. Check the edge filter for signs of plugging or material contamination. Check the o-ring for tearing or deterioration. NOTE: It is recommended that the o-ring on the high pressure connector is replaced.

Install (006-052-026) Carefully push the fuel connector into the head until it stops against the injector. Be sure not to tear the o-ring as the connector is being installed. NOTE: Lubricate the o-ring prior to installation with the engine or vegetable oil.

Install high pressure fuel lines. Refer to Procedure 006-051. Operate engine and check for leaks.

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24 Valve, 8.3 Liter Engine Injectors and Fuel Lines

Fuel Pump Air Bleed Line (006-056) Page 23

Fuel Pump Air Bleed Line (006-056) Preparatory (006-056-000) , 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 (006-056-002) 15 mm, 19 mm Remove banjo capscrew at the distributor drain fitting of the fuel pump. Use two wrenches to prevent the line from being bent.

15 mm, 19 mm Remove the banjo capscrew at the air bleed fitting on top of the fuel pump. It is located on the accumulator module next to the two pumping control valves. Use two wrenches to prevent the air bleed fitting from turning.

Inspect for Reuse (006-056-007) Inspect line for pinches, bends, or damaged connectors.

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24 Valve, 8.3 Liter Engine Page 24

Fuel Pump Air Bleed Line (006-056) Injectors and Fuel Lines

Install (006-056-026) 15 mm, 19 mm Install the banjo capscrew at the air bleed fitting on top of the fuel pump. Use two wrenches to prevent the air bleed fitting from turning. Torque Value: 8 N•m [70 in-lb] Use new sealing washers.

15 mm, 19 mm Install banjo capscrew drain fitting on the fuel pump at the distributor. Use two wrenches to prevent the line from being bent. Torque Value: 8 N•m [70 in-lb] Use new sealing washers.

Start the engine and check for fuel leaks at the air bleed line connections.

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Section 10 Chapter 13

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