INDUSTRIAL INJECTION PN 237603 5.9 Cummins Fuel Rail Plug Instruction Manual
- June 13, 2024
- INDUSTRIAL INJECTION
Table of Contents
INDUSTRIAL INJECTION PN 237603 5.9 Cummins Fuel Rail Plug
WARNING : Please read all of the steps before installation. Cleanliness is extremely important anytime you are working with diesel fuel systems. Prior to installing, clean the area around the location you are going to be removing parts from. This is critical to avoid any possible dirt or debris getting into the fuel system. Common rail fuel systems are sensitive due to tight tolerances and introducing debris can cause premature part failure.
Items needed for installation
• Quality 3/8 torque wrench rated to 60 ft-lbs
• 26mm Extra deep socket and rachet
• 24mm Extra deep socket
• 19mm socket
The factory rail pressure relief valve uses two seals on the banjo bolt located on the top of the valve. The replacement part number for these seals is Cummins PN# 3963988.
Fuel Rail Plug Installation
- Disconnect the battery’s and make sure the engine is cool to the touch.
- Locate the rail pressure relief valve located on the fuel rail behind the intake horn.
- Clean the area around the rail and valve to avoid any contamination during installation.
- Use a 19mm socket to remove the banjo bolt located on top of the valve, be cautious of the seals on the banjo bolt not to drop them if you plan to reuse them.
- Use the 24mm deep socket to remove factory rail pressure relief valve.
- Install the Industrial Injection Rail plug (PN 237603) by lubricating the threads of the plug and start the threads by hand to make sure they are lined up properly.
- Use torque wrench with the 26mm socket and tighten to 60 ft-lbs (81 Nm).
- Install sealing washer on the banjo bolt and insert into the fuel line, then install the other sealing washer between the rail plug and the fuel line.
- Torque banjo bolt to 18 ft-lbs (5 Nm).
Once this is done make sure the area around the plug is clean and dry, turn the key to the ACC position. Let the truck sit with key in ACC for 15-30 sec to let the fuel system purge any air that was introduced into the high- pressure fuel system. Start the engine and inspect for leaks.
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