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Trainings

Select Service Tools

Recommended Cummins® Service Tools
Contact cleaner, Part Number 3824510
Clean care kit, Part Number 4919073
Additional Service Items
No additional service items required.

Initial Check
Use the following procedure for details on injector drain and
leakage measurements. Refer to Procedure 005-236 in
Section 5. (/qs3/pubsys2/xml/en/procedures/417/417-005-236-
tr.html)

Preparatory Steps
 CAUTION 
Clean all fittings before disassembly. Dirt or contaminants
can damage the fuel system.

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Before servicing any fuel system components (such as fuel

lines, fuel pump, injectors, and so forth), which will 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.

Clean the injector supply line connections and mating

components with contact cleaner, Part Number 3824510 or
equivalent.

To prevent damage from debris and 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.

 WARNING 
High pressure fuel spray can cause serious injury or
death.

 WARNING 
When servicing the engine do not use the starting motor
to rotate the engine with a high-pressure fuel system joint
open. Rotating the engine can create highly pressurized
fuel in the fuel system. 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 fuel pressure. Refer to Procedure 006-081
in Section 6. (/qs3/pubsys2/xml/en/procedures/417/417-006-
081.html)

Keep hands clear of the line when loosening the fuel rail nut.

Tighten the fuel rail nut.

Torque Value: 25 n•m [ 221 in-lb ]

Note : A machined slot in this fitting directs the fuel

spray toward the inboard side of the fuel rail.

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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.

 WARNING 
Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches
out of the work area and areas sharing ventilation to reduce the possibility of sever
personal injury or death when working on the fuel system.

Disconnect the batteries. See equipment manufacturer service information.

Disconnect the high-pressure fuel lines. Refer to Procedure 006-051 in Section 6.
(/qs3/pubsys2/xml/en/procedures/417/417-006-051.html)
Any open fuel connectors must be closed immediately with clean protection caps.
Remove the rocker lever cover. Refer to Procedure 003-011 in Section 3.
(/qs3/pubsys2/xml/en/procedures/417/417-003-011-tr.html)

Remove
 CAUTION 
When removing the injector, care must be taken not to
damage the injector tip.

Note : If possible, provide a work area that will not have

flying debris or dust. Gently place the removed
injector(s) on a clean work table or container that has
been cleaned of debris and oils. Immediately cover
each injector to prevent contamination. Cover the
engine if it will be left unattended to prevent
contamination.
Note : Neighboring work areas may inadvertently
contaminate the work area with debris from compressed
air, air tools, or cleaning.

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Reused injectors must be installed with the same cylinder

each time the injector is removed. Mark or tag the fuel injector
with the cylinder number to keep track of the correct position of
each fuel injector.
Remove the injector actuator wire nuts and wires from the
injector.

Loosen and remove the injector hold-down capscrew.

A small heel pry bar can also be used to pry up the injector. Pry
up the injector hold-down flange (part of the injector body just
above the cylinder head casting).

Remove the injector hold-down clamp from the injector.

Remove the injector from the cylinder head.

Apply a protective cap to the injector nozzle.

Insert a blind plug to prevent dust or debris from entering the

engine through the cylinder head.

Reused injectors must be installed with the same cylinder

each time the injector is removed. Mark or tag the fuel injector
with the cylinder number to keep track of the correct position of
each fuel injector.

Clean and Inspect for Reuse

 WARNING 

When using solvents, acids, or alkaline materials for

cleaning, follow the manufacturer’s recommendations for
use. Wear goggles and protective clothing to reduce the
possibility of personal injury.

 CAUTION 
Overheating will cause the nozzle to turn a dark yellow/tan
or blue color resulting in injector damage, depending on
the degree of overheating.

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 CAUTION 

Do not use any abrasives (such as glass beading, sand

paper, emery cloth, Scotch-Brite™ pads, and so forth) or
metallic items (including wire brushes made of any
metallic material) to clean the injectors. The use of any
cleaning method other than safety solvent and a soft,
clean, lint-free cloth will damage the nozzle holes and
cause performance issues.

The injector shaft and nozzle shall be cleaned in an ultrasonic

bath with a safe, aqueous cleaning agent.

Remove the protective cap from the injector nozzle.

Place the injector in the ultrasonic bath in the vertical position.

The high-pressure fuel connector and electrical connection
must not contact the cleaning solution.

A new fine lint free cleaning cloth may also be used to remove
any dirt residue.

Do not remove the protection caps from the fuel inlet and drain
connectors during cleaning.

Inspect the injector tip for carbonization or corrosion.

Check for terminal damage to the solenoid.

Inspect the injector inlet and high-pressure connector tip for

damage.

Overheating will cause the nozzle to turn a dark yellow/tan or

blue color, depending on the degree of overheating.

Inspect the injector o-rings for damage and replace if

necessary.

Resistance between the terminals must be less than 3 ohms.

Install
 CAUTION 

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When installing the injector, care must be taken not to

damage the injector tip.

Note : If the injector solenoid shipping cap is not used

to install the injector, be careful that pressure is not
placed on the wire terminals. Wire terminals can break
off if they are used to push on the injector.
Record the injector trim codes that are listed on each injector.

Record the cylinder location where each injector will be

installed.

Note : The injector trim codes are nine-character

alphanumeric codes, located on the solenoid at the top
of the injector.

Remove the blind plug installed to prevent dust or debris from

entering the engine.

Make sure the injector bore is clean.

Ensure o-ring and injector seal are properly installed.

Lubricate injector o-ring with clean engine oil.

Install injector hold-down clamp on injector before installing

injector into the bore.

Use injector solenoid shipping cap to ensure injector is seated

in the injector bore.

Install injector hold-down capscrew. Do not tighten beyond

hand-tight at this time.

Repeat process to loosely install the other five injectors.

Install rocker lever cover without the oil seal. Tighten one
mounting capscrew on each side of the cover. Refer to
Procedure 003-011 in Section 3.
(/qs3/pubsys2/xml/en/procedures/417/417-003-011-tr.html)
Note : The rocker lever cover must be installed without
the oil seal. If this procedure is performed with the oil
seal installed on the rocker lever cover the injectors
may not align properly, causing oil and/or fuel leaks.
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Connect injector end of one of the high-pressure fuel lines to

injector. Use injector end nut as a guide and center injector in
the grommet.

Remove high-pressure fuel line from injector and repeat

process for all six injectors.

Remove rocker lever cover and install the oil seal. Refer to
Procedure 003-011 in Section 3.
(/qs3/pubsys2/xml/en/procedures/417/417-003-011-tr.html)

Tighten the injector hold-down clamp capscrew.

Torque Value:
Injector Hold-down Clamp Capscrews 65 n•m [ 48 ft-lb ]
Install the injector actuator wires and nuts onto the injector.
Note : Align the injector wires so they will not interfere
with each other or the rocker levers. If a rocker lever is
able to come into contact with the injector harness, it
will rub through the wire insulation and cause injector
circuit fault codes.
Tighten the nuts.

Torque Value:
Injector Actuator Wire Nuts 2 n•m [ 18 in-lb ]
Repeat the process to install the other five injectors.

Finishing Steps
 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.

Trim Code Installation Instructions: INSITE™ 8.2.0 and

Newer
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1. Connect the batteries. See equipment manufacturer

service information.
2. Connect INSITE™ electronic service tool to the Engine
Control Module (ECM).
3. Select "Advanced ECM Data".
4. Select "High-Pressure Common Rail Injector Setup".
5. Read the information listed under the "High-Pressure
Common Rail Injector Setup" and "Instructions" headings.

1. Click on the "New Barcode" section for the respective

cylinder and enter the new barcode.
2. After all the injector trim information is entered, select
"Apply". Turn the keyswitch OFF, then press the "OK"
button to send the new barcode(s) to the ECM.

After INSITE™ electronic service tool reconnects with the

ECM, verify that the "Change Status" = "Success".

If "Change Status" = "Error Occurred", "Invalid Barcode",

"Invalid Cylinder Number", or "Duplicate Barcode", check for
the following:

Verify the correct injector trim code is recorded from the

injector.
Re-enter the trim codes.

Clear all inactive faults.

Install the rocker lever cover. Refer to Procedure 003-011 in Section 3.

(/qs3/pubsys2/xml/en/procedures/417/417-003-011-tr.html)
Install the high-pressure fuel lines. Refer to Procedure 006-051 in Section 6.
(/qs3/pubsys2/xml/en/procedures/417/417-006-051.html)
Operate the engine and check for leaks.

Last Modified: 19-Dec-2022

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