QuickServe Online | (4022256) QSL9 CM2250 Service Manual https://quickserve.cummins.

com/qs3/portal/service/manual/en/4022256/

(/qs3/pubsys2/xml/en/manual/4022256/4022256-titlepage.html)

This procedure refers to the Cummins Common Rail fuel

system.

WARNING

Wear appropriate eye and face protection when using

compressed air. Flying debris and dirt can cause
personal injury.

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.

WARNING

When using a steam cleaner, wear safety glasses or a

face shield, as well as protective clothing. Hot steam

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can cause serious 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 component 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.

Clean the fuel pump and surrounding area. Refer to

Procedure 000-009 in Section 0. (/qs3/pubsys2/xml/en
/procedures/99/99-000-009.html)
Use electrical contact cleaner, Part Number 3824510, or
equivalent, to throughly clean all fuel lines before
removal from the engine. Clean the connector fittings to
remove as much debris as possible. It is very important
that extra care is taken to keep the fuel connections
clean during removal and installation. Refer to
Procedure 204-008 in Section i. (/qs3/pubsys2/xml/en
/procedures/99/99-204-008.html)
Make sure that debris, water, steam, or cleaning solution
does not get inside the fuel system.

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.

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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.

Tighten the fuel rail nut.

Torque Value: 65 nm [ 48 ft-lb ]

Note : A machined slot in this fitting directs the fuel

spray towards the engine block.

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 battery. Refer to the OEM service

manual.
Remove the fuel supply lines from the fuel pump. Refer
to Procedure 006-024 in Section 6. (/qs3/pubsys2
/xml/en/procedures/45/45-006-024-tr-qslt4i.html)
Remove the fuel drain line from the fuel pump. Refer to
Procedure 006-013 in Section 6. (/qs3/pubsys2/xml/en
/procedures/45/45-006-013-tr-qslt4i.html)
Disconnect the engine harness from the fuel pump
actuator. Refer to Procedure 019-117 in Section 19.
(/qs3/pubsys2/xml/en/procedures/100/100-019-117.html)
Remove the fuel pump gear access cover.

Remove the fuel pump upper support bracket by removing

the two bolts (1) and (2).

The upper support bracket is located on the fuel pump

actuator housing. Refer to Procedure 005-228 in Section 5.

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(/qs3/pubsys2/xml/en/procedures/45/45-005-228-tr.html)

Locate top dead center for cylinder Number 1 by barring the

engine until the line on the fuel pump gear aligns with the
front cover mark for top dead center.

Remove the fuel pump gear nut and washer.

Use fuel pump gear puller, Part Number 3824469, to pull the
fuel injection pump drive gear loose from the fuel pump drive
shaft.

Remove the four mounting nuts that hold the fuel pump to
the gear housing.

Remove the fuel pump.

The dowel pin in the fuel pump drive shaft must not be
sheared.

If the dowel is sheared, the camshaft housing or fuel pump

must be replaced, and the drive gear must be replaced.

Be sure the pilot o-ring is not cut or otherwise damaged.

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The pump oil supply o-ring must be replaced. Make sure it is

not damaged.

Make sure the engine is at Number 1 cylinder, top dead

center. The fuel pump gear timing mark must align with the
top dead center mark on the front cover.

Make sure the o-ring seals for the oil feed orifice (A) and pilot
(B) are installed correctly.

Lubricate the pilot o-ring (B) with clean engine oil.

Clean the nose of the drive shaft and the fuel pump gear
inside diameter with electrical contact cleaner, Part Number
3824510, or equivalent.

The fuel pump drive gear inside diameter and the drive shaft
outside diameter must be clean and dry before installing the
gear.

Slide the fuel injection pump shaft through the drive gear and
position the fuel injection pump flange onto the mounting
studs.

Make sure the dowel pin in the drive shaft lines up with the
keyway in the fuel injection pump gear.

Installation sequence for fuel pump actuator housing

mounted support bracket:

1. Install the pump mounting nuts (leave loose).

2. Install the bolt to the cylinder head (1) and the bolt
through the pump flange (2) into the support bracket
(leave loose).

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3. Tighten the pump mounting nuts.

Torque Value: 44 nm [ 32 ft-lb ]

1. Tighten the bolt into the cylinder head (1).

Torque Value: 65 nm [ 48 ft-lb ]

1. Tighten the bolt into the pump flange (2).

Torque Value: 80 nm [ 59 ft-lb ]

Tighten the fuel injection pump drive gear nut.

Torque Value: 180 nm [ 133 ft-lb ]

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 access cover in the front cover.

Install the fuel supply lines to the fuel pump. Refer to
Procedure 006-024 in Section 6. (/qs3/pubsys2/xml/en
/procedures/45/45-006-024-tr-qslt4i.html)
Install the fuel drain line to the fuel pump. Refer to
Procedure 006-013 in Section 6. (/qs3/pubsys2/xml/en
/procedures/45/45-006-013-tr-qslt4i.html)
Connect the wire harness to the fuel pump actuator.
Refer to Procedure 019-117 in Section 19. (/qs3/pubsys2
/xml/en/procedures/100/100-019-117.html)
Connect the batteries. Refer to the OEM service manual.

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Operate the engine and check for leaks.

Last Modified: 11-Jun-2014

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