S-57

AXXENXION
This pump is supplied with the latest style pressure and temperature sensors.
Modifications to vehicle wiring harness may be required. Use the chart below to
find the correct wire harness modification kit.

Original vehicle wiring configuration

Style #1
Combined pressure and temperature sensor.
Use kit part number #142-075-0006
CUM4089442

Style #2
Separate pressure and temperature
sensor where the pressure sensor
does not have a pigtail.
Use kit part number # 142-075-0005
CUM4089441

Style #3
Separate pressure and temperature
sensor where the pressure has a pigtail .
No wiring modification required.

Rebuilt pumps will come with the latest

Style pressure sensor (Style #3)
8/12/2020 CAPS Fuel Pressure Sensor Kit

Service Bulletin
Service Bulletin Number: 4021294-01 Released Date: 27-jan-2003
CAPS Fuel Pressure Sensor Kit

CAPS Fuel Pressure Sensor Kit 4089441

Purpose
This is a product improvement and not subject to campaign.

This service bulletin is a revision to the previous installation procedure to accommodate a redesigned fuel pressure sensor
and engine harness bracket.
This service bulletin provides procedures for installing the CAPS fuel pressure sensor kit, Part Numbers 4089441 and
4025130. The modifications below are needed to accommodate the new engine harness bracket, injection control valve
(ICV) extension, and p-clip. This kit is used when replacing a failed fuel pressure sensor on engines originally built with the
two-sensor system (separate fuel pressure and fuel temperature sensors). If a fuel pressure sensor is being replaced on an
engine originally built with the combination fuel pressure/temperature sensor, kit Part Number 4089442 and 4025130 can
be used. Refer to Service Bulletin 4021293 (/qs3/pubsys2/xml/en/bulletin/4021293.html).

The electrical repair connector, Part Number 3164188, updates the wiring harness. It requires cutting off the old connector
and splicing in the new one. Production engines began incorporating this change in September 2000. Also, a new engine
wiring harness will be released for production and service. If the wiring harness must be changed on an engine built before
September 2000, the sensor also must be replaced.

Table 1, CAPS Fuel Pressure Sensor Kit, Part Number 4089441

Item Number Part Number Description Quantity
1 3164188 Electrical repair connector 1
2 3965124 Engine harness bracket 1
Engine harness bracket bolt
3 3913638 1
for p-clip
Injection control valve (ICV)
4 3408573 1
extension
Injection control valve (ICV)
5 3966193 1
extension p-clip

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8/12/2020 CAPS Fuel Pressure Sensor Kit

Table 1, CAPS Fuel Pressure Sensor Kit, Part Number 4089441

Item Number Part Number Description Quantity
Wire tie for injection control
6 3062329 valve (ICV) extensions p- 1
clip
Not shown 4021294 Service Bulletin 1

06(100227

Table 2, CAPS Fuel Pressure Sensor Kit, Part Number 4025130

Item Number Part Number Description Quantity
1 3408551 Pressure sensor 1
2 4076375 Seal washer 1

Remove
Disconnect the engine wiring harness from the existing high-pressure sensor.
Disconnect the pump control valve harness connection.

Disconnect the injection control valve (ICV) harness connection.

Remove the existing fuel pressure sensor.

Remove the seal washer.

Pressure Sensor - Installation

Adhere the small seal washer (2) to the new sensor (1) using a small amount of
Lubriplate™ grease, Part Number 3822934.
Carefully screw the pressure sensor into the accumulator.

Use a 1-1/16-inch crowfoot to tighten the new sensor.

When tightening the sensor, a crush of the seal washer is felt.

Torque Value: 68 n•m [ 50 ft-lb ]

Relocate Engine Harness

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8/12/2020 CAPS Fuel Pressure Sensor Kit

Locate the fuel pressure sensor, temperature sensor, and injection control valve
(ICV) connectors and remove them from the inside of the rate shape tube
assembly.

Remove the p-clip attaching the engine harness to the fuel pump support brace.
Remove the p-clip from harness, and set aside to be installed later.

05d00757

Jumper Harness - Installation

Locate the wiring harness from the existing fuel pressure sensor. Attach one
label to each of the three wires in the harness connector as described below:
1. Label pin A with an A.
2. Label pin B with a B.
3. Label pin C with a C.

The illustration shows the labels of the wires from the front of the connector.

Cut off all three wires from the high-pressure sensor connector.
Strip the insulation from each of the three wires.

Located on the electrical repair connector are the correct letters. Match the
labeled wires together.

Make sure the electrical repair connector butt and the wire are fully installed
before crimping.

1. A connects to the red-striped wire on the jumper harness.

2. B connects to the black wire on the jumper harness.
3. C connects to the green-striped wire on the jumper harness.

The wiring layout of the pressure sensor is not like other Cummins pressure
sensors. Crimp the wires together as follows:

A. 5 VDC supply
B. Return
C. Signal.
Crimp the matching wires together using the supplied butt connectors of the
jumper harness.
Use the flameless shrink jet tool, Part Number 3163112, to heat the butt
connectors and seal the connection.

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8/12/2020 CAPS Fuel Pressure Sensor Kit

After installing the jumper harness, wrap the excess wires in electrical tape,
then route the wires through convolutes terminating end. Continue to wrap
/
electrical tape around the conduit at least two times. This will ensure the wires 7
do not fall out and short to ground, or chaff against convolutes sharp edges.
The harness on the left in the illustration shows the harness modified outside
the convolute.

The harness on the right in the illustration shows the harness modified inside
05d00765
the convolute.

Remove
Remove the fuel line bracket 10-mm center capscrew and keep for reuse.

Install
Install the engine harness bracket, Part Number 3965194.
Torque Value: 24 ± 4 n•m [ 212 ± 4 in-lb ]

Route the engine harness through the p-clip that was removed from the fuel
pump support brace.

Install the p-clip on the engine harness bracket using a 8-mm bolt (bracket is
threaded for supply bolt). Make sure the p-clip is facing away from the pump.

The engine harness should extend 80-mm out of the p-clip.

Secure the p-clip.

Connect the engine harness to the injection control valve (ICV) connector using
an injection control valve (ICV) extension harness, Part Number 3408573.

P-clip the injection control valve (ICV) extension harness to the fuel pump
support bracket using a p-clip, Part Number 3966193.

Position the p-clip for the injection control valve (ICV) extension harness over
the fuel inlet line. Once properly positioned, (see illustration) secure the wire tie,
Part Number 3966193. The wire tie keeps the extension harness from moving in
the p-clip.

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Connect all engine harness connections and make sure the fuel pressure
sensor wires and injection control valve (ICV) wires are not rubbing on the
pump and/or stretched too tight. If wires are rubbing or stretched, rotate the
harness or reposition the p-clips to accommodate a better fit.

05d00763

Last Modified: 11-Feb-2003

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