Verify that the new injector sealing washer is the correct thickness.
NOTE: Sealing washers are configured in a flat (1) or saucer (2) shape. When replacing the injector sealing washer, only the saucer style washer must be used; not the flat style washer.
Verify a new and correct sealing washer has been installed on the tip of the injector.
NOTE: A used sealing washer may not have the “saucer” profile due to installation.
Make sure the injector bore is clean and that only one sealing washer is installed on the injector nozzle.
The rounded edge of the injector hold-down clamp is positioned toward the rocker levers. The fuel inlet hole on
the injector must face the intake side of the engine.
Lubricate a new injector a-ring with clean engine oil.
Align 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 the injector solenoid shipping cap is not used to install the injector, be careful that pressure is not placed
on the wire terminals. The wire terminals can break off if used to push on the injector.
Lubricate the fuel connector a-ring and the threads on the fuel connector retaining nut with clean engine oil.
Carefully insert the fuel connector. Align the guide with the anti-rotation slot in the cylinder head at the 12-o’clock
position.
Start the high-pressure fuel connector retaining nut, but do not tighten.
NOTE: To prevent the possibility of damage, use even, axial force when installing. Be sure to not tear the a-ring
as the connector is being installed.
Install the injector hold-down clamp and injector hold down capscrews, but do not tighten.
Apply the preliminary torque to the fuel connector retaining nut to begin seating the fuel connector to the injector.
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 capscrews.
NOTE: Be sure to tighten the hold-down capscrews evenly. Verify that the gap between the hold-down clamp and the injector is equally spaced around the injector body.
Alternate between capscrews, turning 90 degrees per turn until reaching:
Torque Value: 8 N•m [ 71 in-lb ]
Tighten the high-pressure fuel connector retaining nut.
Refer to Procedure 006-052 in Section 6.
NOTE: Do not over-tighten the connector retaining nut.
Over-tightening of the retaining nut can cause the connector to rotate out of the connector retaining slot.
For engines equipped with a rocker lever cover-mounted crankcase breather, the rocker lever cover gasket must
be installed before connecting the injector solenoid wires.
Refer to Procedure 003-011 in Section 3.
For engines equipped with a rear engine-mounted crankcase breather, connect the injector solenoid wires.
Connect the injector solenoid wires to each injector.
Use Cummins® service tool, Part Number 3823208, or a torque wrench, to tighten the solenoid wires.
Torque Value: 1.5 N•m [ 13 in-lb ]
NOTE: Be sure the solenoid wires can not make contact with the rocker levers when installed.