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 running. 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 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 
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.

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
100 cc [3.38 oz]
30 Seconds of Cranking

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.
(/qs3/pubsys2/xml/en/procedures/45/45-006-052-
tr.html)
High-pressure fuel connector damage. Refer to Procedure
006-052 in Section 6.
(/qs3/pubsys2/xml/en/procedures/45/45-006-052-
tr.html)
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 [10.1 oz]
45 Seconds
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.
(/qs3/pubsys2/xml/en/procedures/45/45-006-052-tr.html)
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. (/qs3/pubsys2/xml/en/procedures/45/45-
006-052-tr.html)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. (/qs3/pubsys2/xml/en/procedures/45/45-
006-013-tr.html)
Install all high-pressure fuel lines. Refer to Procedure 006-051
in Section 6. (/qs3/pubsys2/xml/en/procedures/45/45-006-
051-tr.html)
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. (/qs3/pubsys2/xml/en/procedures/45/45-
003-011-tr.html)
Remove the engine brake, if equipped. Refer to Procedure
020-004 in Section 20.
(/qs3/pubsys2/xml/en/procedures/45/45-020-004-
tr.html)
Remove the fuel connector. Refer to Procedure 006-052 in
Section 6. (/qs3/pubsys2/xml/en/procedures/45/45-006-
052-tr.html)

Cummins® Common Rail Fuel System

 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 
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 
Attempting to remove the injector without first removing the
fuel connector will cause damage to the injector body and/or
fuel connector.

Disconnect the batteries. Refer to Procedure 013-009 in

Section 13. (/qs3/pubsys2/xml/en/procedures/45/45-
013-009.html)
Remove the rocker lever cover. Refer to Procedure 003-011
in Section 3. (/qs3/pubsys2/xml/en/procedures/45/45-
003-011-tr.html)
Remove the high-pressure fuel line. Refer to Procedure
006-051 in Section 6.
(/qs3/pubsys2/xml/en/procedures/45/45-006-051-
tr.html)
Remove the engine brake, if equipped. Refer to Procedure
020-004 in Section 20.
(/qs3/pubsys2/xml/en/procedures/45/45-020-004-
tr.html)
Remove the fuel connector. Refer to Procedure 006-052 in
Section 6. (/qs3/pubsys2/xml/en/procedures/45/45-006-
052-tr.html)
Remove the exhaust rocker lever assembly. Refer to
Procedure 003-008 in Section 3.
(/qs3/pubsys2/xml/en/procedures/45/45-003-008-
tr.html)

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.
(/qs3/pubsys2/xml/en/procedures/45/45-006-051-tr.html)

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.

Cummins® Common Rail Fuel System

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
Mechanical Injectors
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
Mechanical Injectors
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 ]

Cummins® Common Rail Fuel System

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.
Torque Value:  15  n•m    [ 133 in-lb ]
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.
Torque Value:  10  n•m    [ 89 in-lb ]

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.
(/qs3/pubsys2/xml/en/procedures/45/45-006-052-tr.html)
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 Procedure 006-052 in
Section 6. (/qs3/pubsys2/xml/en/procedures/45/45-006-
052-tr.html)
Install the rocker lever cover. Refer to Procedure 003-011
in Section 3. (/qs3/pubsys2/xml/en/procedures/45/45-
003-011-tr.html)
Install the high-pressure fuel lines. Refer to Procedure 006-
051 in Section 6.
(/qs3/pubsys2/xml/en/procedures/45/45-006-051-
tr.html)
Operate the engine and check for leaks.

Cummins® Common Rail Fuel System

 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.
(/qs3/pubsys2/xml/en/procedures/45/45-003-008-
tr.html)
Install the engine brake, if equipped. Refer to Procedure
020-004 in Section 20.
(/qs3/pubsys2/xml/en/procedures/45/45-020-004-
tr.html)
 Install the high-pressure fuel lines. Refer to Procedure 006-
051 in Section 6.
(/qs3/pubsys2/xml/en/procedures/45/45-006-051-
tr.html)
Install the rocker lever cover. Refer to Procedure 003-011
in Section 3. (/qs3/pubsys2/xml/en/procedures/45/45-
003-011-tr.html)
Open the fuel supply and return valves. See equipment
manufacturer service information.
Connect the batteries. Refer to Procedure 013-009 in
Section 13. (/qs3/pubsys2/xml/en/procedures/45/45-
013-009.html)
Operate the engine. Check for leaks.

Last Modified:  27-Sep-2017