Instalaçaõ Dos Injetores

Injector Página 1 de 20
006-026 Injector
Initial Check
Cummins® Common Rail Fuel System
WARNING
The fuel pump, high-pressure fuel lines,
and fuel rail contain very high-pressure
fuel. Do not loosen any fittings while the
engine is operating. Wait at least 10
minutes after shutting down the engine
before loosening any fittings in the high-
pressure fuel system to allow pressure to
decrease to a lower level.
CAUTION
Use caution when disconnecting or

removing fuel lines, replacing filters, and
priming the fuel system, that fuel is not
spilled or drained into the bilge area. Do
not drop or throw filter elements into the
bilge area. The fuel and fuel filters must be
discarded in accordance with local
environmental regulations.
CAUTION
Installation of the banjo flow adapter at any

place other than the fuel drain manifold can
cause damage to high pressure fuel
https://qsol.cummins.com/qs2/pubsys2/xml/en/procedures/45/45-006-026-tr.html 07/11/2012
system components.
Return fuel is routed from the injectors, the

fuel rail pressure relief valve, and the fuel
pump head through three different drain lines.
Measurement of fuel injector leakage requires

the use of a fuel return hose, Part Number
3164618.
The tool is used to isolate the leakage from

just the injectors, so it can be measured with
a graduated cylinder.
If necessary, this tool can be constructed

using the steps outlined below.
To make a banjo bolt flow adapter tool, drill

and tap the hex face of a M12 x 1.5 banjo
bolt, Part Number 3903035, or equivalent.
Drill and tap the hex face of the banjo bolt to

the size of a male union (or other hose fitting)
being used (example 1/8-inch NPT hose
barb).
Drill and tap the open end of the banjo bolt for
the installation of a 5/16-24 set screw.
WARNING
Depending on the circumstance, diesel
fuel is flammable. When inspecting or

performing service or repairs on the fuel
system, to reduce the possibility of fire
and resulting severe personal injury,
death or property damage, never
smoke or allow sparks or flames (such
as pilot lights, electrical switches, or
welding equipment) in the work area.
CAUTION

removing fuel lines, replacing filters and
priming the fuel system that fuel is not
spilled or drained into the bilge area. Do
not drop or throw filter elements into the
bilge area. The fuel and fuel filters must
be discarded in accordance with local
environmental regulations.
Remove the M12 banjo bolt that connects

the fuel injector drain line to the fuel drain
manifold.
Install the M12 fuel return hose, Part

Number 3164618, at the fuel drain
manifold.
Route the fuel return hose into a collection

device.
Obtain a graduated cylinder that is marked

in cubic centimeters; example: graduated
beaker, Part Number 3823705, or
equivalent. A kitchen style measurement
cup that is marked in cubic centimeters
(cc's) also works well.
Start the engine and allow the engine to

idle until drain fuel from the injector drain
line begins to flow into the collection
container.
Connect INSITE™ electronic service tool.
If the engine will not start, these

procedures are still valid; however, the
pass/fail specification is different.
If the engine will not start, drain flow must

be measured while engaging the starter
for 30 seconds at a time.
Leakage Specification if Engine Will

Not Start
Maximum Leakage During 30 100 cc
Seconds of Cranking [3.38 oz]
If the injector leakage is excessive during

cranking and the engine will not start,
check the following:
High pressure fuel connector

installation. Refer to Procedure 006-
052 in Section 6.
High pressure fuel connector
damage. Refer to Procedure 006-
052 in Section 6.
Use the fuel leak test tool, Part
Number 3164325, to isolate injectors
from the fuel rail, one at a time.
CAUTION
Fuel is at high pressure during this test.

After connecting the test fitting, close the
engine cover and stand clear of high-
pressure fuel lines.
If the engine will start, the following steps will

determine if the injector drain flow is
excessive.
While the engine is operating at idle, use

INSITE™ electronic service tool High
Pressure Leak Test to create high fuel rail
pressure. INSITE™ electronic service tool will
command 1500 BAR [21,756 psi] fuel rail
pressure while the engine is at idle during this
test.
Record the amount of time it takes for 300

cc [10.1 oz] of fuel to flow from the injector
drain line when performing INSITE™
electronic service tool High Pressure Leak
Test.
Leakage Specification With Engine

operating
Maximum Leakage During 300 cc
45 Seconds [10.1 oz]
If 300 cc [10.1 oz] of fuel leaks from the

injectors in less than 45 seconds, there is
at least one loose or damaged high
pressure fuel connector and/or injector.
NOTE: Fuel temperature and fuel type

will influence this measurement. For
example; as the engine is warmed up
and the injectors become hot, the
leakage rate will increase. Also, low
viscosity fuels, such as kerosene, will
cause the leakage rate to increase. The
above specification is correct for on-
highway diesel fuels where fuel inlet
temperature is less than 49°C [120°F].
After recording the fuel leakage rate, stop

INSITE™ electronic service tool High
Pressure Leak Test and turn the keyswitch
to OFF.
If injector drain flow is excessive, it will be

necessary to isolate the injector(s) or fuel
connector(s) that are damaged or worn.
A loose fuel connector retaining nut results

in a poor seal at the interface between the
fuel connector and the injector. This loose
condition will result in a leak of high-
pressure fuel to the injector drain.
Verify first that the fuel connectors are

properly tightened. Refer to Procedure
006-052 in Section 6.
If loose retaining nut(s) are found, test for

leakage after tightening the retaining nut
(s).
CAUTION
Do not install the isolation tool at the high

pressure pump outlet fitting. Severe engine
damage will result. This tool must only be
installed at the fuel rail for the purpose of
isolating the high-pressure fuel supply from
individual injectors.
CAUTION
Make certain the keyswitch is in the OFF

position (engine not operating) when
loosening or tightening high-pressure fuel
lines.
Use leak test isolation tool, Part Number

3164325, to isolate excessive fuel drainage
from injectors or fuel connectors.
Isolate the injector and fuel connector for

each cylinder by installing the isolation tool
at the fuel rail in place of the high-pressure
fuel line that supplies the fuel connector.
Torque Value: 38 n.m [28 ft-lb]
Record the amount of time it takes for 300

cc [10.1 oz] of fuel to flow from the injector
drain line while the engine is operating.
Use INSITE™ electronic service tool High
Pressure Leak Test. Do this up to six (6)
times, once while each line is isolated.
If isolating a single injector and high-

pressure fuel connector causes the
leakage time to increase significantly
compared to the rest of the set, that
injector and fuel connector must be
inspected.
Inspect the suspect fuel connector. Refer

to Procedure 006-052 in Section 6. If the
fuel connector is not damaged, replace
both the injector and the fuel connector.
Remove the M12 diagnostic flow adapter

from the fuel drain manifold and install the
M12 banjo. Refer to Procedure 006-013 in
Section 6.
Install all high-pressure fuel lines. Refer to

Procedure 006-051 in Section 6.
Operate the engine and check for leaks.
Preparatory Steps
CAPS Fuel System
CAUTION
Attempting to remove the injector

without first removing the fuel connector
will cause damage to the injector body
and/or fuel connector.
Remove the rocker lever cover.

Refer to Procedure 003-011 in
Section 3.
Remove the engine brake, if
equipped. Refer to Procedure 020-
004 in Section 20.
Remove the fuel connector. Refer to
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.
CAUTION

removing fuel lines, replacing filters,
and priming the fuel system, that fuel is
not spilled or drained into the bilge
area. Do not drop or throw filter
elements into the bilge area. The fuel
and fuel filters must be discarded in
accordance with local environmental
regulations.
CAUTION
Attempting to remove the injector

without first removing the fuel connector
will cause damage to the injector body
and/or fuel connector.
NOTE: All fuel system diagnostics

procedures and component
specifications have been moved. Refer
to Procedure 005-236 in Section 5.
Disconnect the batteries. Refer to

Remove the rocker lever cover.
Section 3.
Remove the high-pressure fuel line.
Section 6.
Remove the engine brake, if
equipped. Refer to Procedure 020-
004 in Section 20.
Remove the fuel connector. Refer to
Remove the exhaust rocker lever
assembly. Refer to Procedure 003-
008 in Section 3.
Remove
CAPS Fuel System
Remove the injector hold-down clamp

capscrew that is nearest the exhaust
manifold side of the engine.
Remove the injector hold-down clamp.
Remove the high-pressure fuel connector.

Refer to Procedure 006-051 in Section 6.
Use the injector puller, Part Number

3825156, to pull the injector out of the
head.
Alternatively, a rocker cover capscrew can

be installed into the top of the injector and
used to pull the injector from the cylinder
head.
Be sure the injector seal washer is

removed from the injector bore.
Disconnect the injector wire harness from

the injector.
Remove the two injector hold-down clamp

capscrews and remove the injector hold-
down clamp.
Use a small heel-bar to pry up on the

injector clamp hold-down flange (part of
the injector body just above the cylinder

head casting).
Test
Mechanical Injectors
WARNING
While testing the injectors, keep hands
and body parts away from the injector
nozzle. Fuel coming from the injector is
under extreme pressure and can cause
serious injury by penetrating the skin.
Install the injectors on an injector test

stand. Open the bypass valve for the
pressure gauge, so the spray pattern can
be checked.
Use the injector test fixture, Part Number

3162269, with the injector nozzle test, Part
Number 3376946.
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.

It is possible that only a single hole has
been damaged, resulting in degraded
engine performance.
Close the bypass valve for the pressure

gauge and operate the test stand lever to
check the nozzle opening pressure. There
must be a good crisp "pop" when the
nozzle opens and the pressure must be
within the specification for the assembly
number.
The injector will pop between 275 bar

[3,989 psi] and 300 bar [4,351 psi].
If the nozzle opening pressure is excessively

low and/or the nozzle sprays excessive fuel,
the injector needle can be sticking. The
needle can 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.
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 [145 psi]of the
opening pressure of the nozzle.
A drop of fuel must not form within 15

seconds.
Disassemble
Place the injector in the injector clamp and

remove the nozzle retaining nut.
NOTE: Injectors covered under

warranty by the manufacturer must not
be repaired. See the manufacturer's
warranty instructions.
Remove the nozzle, intermediate plate,

spring, and shims from the 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 avoid personal injury.
WARNING
Some solvents are flammable and toxic.

Read the manufacturer's instructions
before using.
CAUTION
Do not use any abrasives (such as

glass beading, sand paper, emery cloth,
Scotch-Brite™ pads, etc) 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.
Clean the injector tip and body with safety

solvent and a soft, clean cloth.
Assemble
Clean the injector internal components

with clean diesel fuel and a clean cloth.
Make sure there is no debris in the internal
parts of the injector.
Install shims, as necessary, to modify the

nozzle opening pressure. More shims
raise the nozzle opening pressure, fewer
shims lower the nozzle opening pressure.
Install the spring, button, intermediate

plate, and nozzle/needle.
Make sure 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
CAPS Fuel System
NOTE: If a new injector is being

installed, a new fuel connector must be
used
Make sure the injector bore is clean and

that only one (1) sealing washer is
installed on the injector nozzle.
Lubricate the injector o-ring with clean

engine oil.
Place the injector in the head in the proper

orientation.
Place the injector hold-down clamp on top

of the injector and make sure the injector
is fully seated in the injector bore.
Install the injector hold-down clamp and

tighten.
Torque Value: 10 n.m [89 in-lb]
Make sure the injector bore is clean and

that only one (1) sealing washer is
installed on the injector nozzle.
Lubricate the injector o-ring with clean

engine oil.
Place the injector in the cylinder head in

the proper orientation (fuel inlet toward the
high-pressure fuel connector).
Use the injector shipping sleeve to make

sure the injector is seated in the injector
bore.
NOTE: If a new injector is being

installed, a new fuel connector must be
used.
Start the injector hold-down clamp
capscrews, and tighten hand-tight.
Install the high-pressure fuel connector,

making sure the end of the high-pressure
fuel connector is in the injector inlet port.
NOTE: The high-pressure fuel

connector should click into place if it is
seated in the injector inlet port
correctly.
Start the high-pressure fuel connector

retaining nut and tighten partially.
NOTE: This is not the final torque for

the high-pressure fuel connector
retaining nut.
Tighten the injector hold-down clamp

capscrews.
NOTE: Make sure to tighten the hold-

down clamp capscrews evenly. Check
to make sure the gap between the hold-
down clamp and the injector is equally
spaced around the injector body.
Tighten the high pressure fuel connector

retaining nut.
Use the following procedure for the final

torque value. Refer to Procedure 006-052
in Section 6.
NOTE: The high-pressure fuel

connector must be properly tightened
or an internal fuel leak can result,
causing poor engine performance. A
torque wrench must be used.
CAUTION
Do not overtighten the injector harness.

The injector terminals will be damaged
if excessively over-tightened.
Install the injector wiring harness to the

injector.
Torque Value: 1.25 n.m [11 in-lb]
NOTE: Orient the injector wires so they

will not interfere with a rocker lever or
engine brake housing. If the 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.
NOTE: Polarity of the wiring is not

significant. The signal and return wires
can be connected to either injector
terminal.
Finishing Steps
CAPS Fuel System
Install the fuel connector. Refer to

Install the rocker lever cover. Refer
Install the high pressure fuel lines.
Section 6.
Operate the engine and check for
leaks.
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 exhaust rocker lever

assembly. Refer to Procedure 003-
008 in Section 3.
Install the engine brake, if equipped.
Section 20.
Install the high pressure fuel lines.
Section 6.
Install the rocker lever cover. Refer
Open the fuel supply and return
valves. Refer to the OEM service
manual.
Connect the batteries. Refer to
Operate the engine and check for
leaks.
Last Modified: 14-Apr-2011
Copyright © 2000-2010 Cummins Inc. All rights reserved.

Instalaçaõ Dos Injetores

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Injector Página 1 de 20

Use caution when disconnecting or

Installation of the banjo flow adapter at any

Return fuel is routed from the injectors, the

Measurement of fuel injector leakage requires

The tool is used to isolate the leakage from

If necessary, this tool can be constructed

To make a banjo bolt flow adapter tool, drill

Drill and tap the hex face of the banjo bolt to

fuel is flammable. When inspecting or

Use caution when disconnecting or

Remove the M12 banjo bolt that connects

Install the M12 fuel return hose, Part

Route the fuel return hose into a collection

Obtain a graduated cylinder that is marked

Start the engine and allow the engine to

Connect INSITE™ electronic service tool.

If the engine will not start, these

If the engine will not start, drain flow must

Leakage Specification if Engine Will

If the injector leakage is excessive during

High pressure fuel connector

Fuel is at high pressure during this test.

If the engine will start, the following steps will

While the engine is operating at idle, use

Record the amount of time it takes for 300

Leakage Specification With Engine

If 300 cc [10.1 oz] of fuel leaks from the

NOTE: Fuel temperature and fuel type

After recording the fuel leakage rate, stop

If injector drain flow is excessive, it will be

A loose fuel connector retaining nut results

Verify first that the fuel connectors are

If loose retaining nut(s) are found, test for

Do not install the isolation tool at the high

Make certain the keyswitch is in the OFF

Use leak test isolation tool, Part Number

from injectors or fuel connectors.

Isolate the injector and fuel connector for

Torque Value: 38 n.m [28 ft-lb]

Record the amount of time it takes for 300

If isolating a single injector and high-

Inspect the suspect fuel connector. Refer

Remove the M12 diagnostic flow adapter

Install all high-pressure fuel lines. Refer to

Operate the engine and check for leaks.

Attempting to remove the injector

Remove the rocker lever cover.

Cummins® Common Rail Fuel System

attach the negative (-) battery cable

Use caution when disconnecting or

Attempting to remove the injector

NOTE: All fuel system diagnostics

Disconnect the batteries. Refer to

Remove the injector hold-down clamp

Remove the injector hold-down clamp.

Remove the high-pressure fuel connector.

Use the injector puller, Part Number

Alternatively, a rocker cover capscrew can

Be sure the injector seal washer is

Cummins® Common Rail Fuel System

Disconnect the injector wire harness from

Remove the two injector hold-down clamp