THOROUGHBRED DIESEL Stock Injector Pack Installation Guide

THOROUGHBRED DIESEL Stock Injector Pack

Product Specifications

• Product: Fuel Injector for 2003-2018 Cummins 5.9L/6.7L
• Injector Type: Solenoid-actuated high-pressure fuel injector
• Injector Mounting: Vertically mounted into a bored hole in the cylinder head
• Injector Sealing Washer Thickness: 1.5mm (.060)
• Torque Specifications:
  • Fuel Injector Hold Down Bolts: 44 in. lbs. preliminary, 89 in. lbs. final
  • High-Pressure Connector Retaining Nut: 11 ft. lbs. preliminary, 44 ft. lbs. final
  • Injector Solenoid Connector Nuts: 11 in. lbs.
  • Exhaust Rocker Arm Assembly: 27 ft. lbs.

Product Usage Instructions

1. Depress the handle downward to remove the fuel injector straight up from the cylinder head bore.
2. Remove and discard the old injector sealing washer located on the tip of the injector.
3. Install a new shim (washer) of 1.5mm thickness to the bottom of the injector with a light coating of clean engine oil to keep it in place.
4. Apply a small amount of clean engine oil to the o-ring of the injector.
5. Install the injector into the cylinder head with the male connector port facing the intake manifold, ensuring proper seating.
6. Tightening sequence:
7. Preliminary tighten fuel injector hold down clamp bolts to 44 in. lbs.
8. Relieve bolt torque and leave bolts threaded in place.
9. Preliminary tighten high-pressure connector and retaining nut to 11 ft. lbs.
10. Alternately tighten injector hold-down bolts to 89 in. lbs.
11. Finally, tighten the high-pressure connector and retaining nut to 44 ft. lbs.
12. Connect injector solenoid wires and nuts to the top of injectors, tightening nuts to 11 in. lbs.
13. Install exhaust rocker arm assembly to 27 ft. lbs.
14. Set exhaust valve lash.
15. Install a high-pressure fuel line following torque specifications and use a secondary backup wrench while torquing the fitting.
16. Install valve cover and breather assembly.
17. Connect negative battery cables to both batteries.

FAQ

• Q: Can I reuse the old injector sealing washer?
• A: No, it is recommended to remove and discard the old sealing washer and install a new one during reassembly for proper sealing.
• Q: What should I do if I over-tighten the connector nuts on the injector solenoid wires?
• A: Be very careful not to over-tighten these nuts as it may cause damage to the fuel injector. If over-tightened, consider replacing the damaged parts before proceeding with installation.

FUEL INJECTOR REMOVAL AND INSTALLATION

2003-2018 CUMMINS 5.9L/6.7L
There are six individual solenoid-actuated high-pressure fuel injectors. The injectors are vertically mounted into a bored hole in the top of the cylinder head. This bored hole is located between the intake/exhaust valves. High- pressure connectors are mounted to the side of the cylinder head. connect each fuel injector to each high-pressure fuel line.

Removal

1. Disconnect negative battery cables from both batteries. Cover and isolate the ends of the cables.
2. Remove the breather assembly.
3. Remove the valve cover.
4. Remove the high-pressure fuel line connecting the fuel injector rail to the high-pressure connector.
5. A connector retainer nut is used on each connector tube. Remove this by unthreading from the cylinder head.
6. Using special high-pressure connector removal tool #9015 (recommended by Cummins), remove necessary high-pressure connectors from the cylinder head. Tool #9015 threads onto the connector tube. Use the tool to pry the connector tube from the cylinder head. These should be removable by hand.
7. Remove necessary exhaust rocker arm assemblies. Keep these in order.
8. Disconnect injector solenoid wire nuts at the top of injectors.
9. Remove two fuel injector hold-down clamp bolts at each injector being removed.
10. a- Special tool #9010 (recommended by Cummins) is equipped with two clamshell clamps, a sliding retainer sleeve to retain the clamshell clamps, a two-piece mounting stud and a pivoting handle.
    • The rocker housing is bolted to the top of the cylinder head. The mounting stud from tool #9010 was meant to temporarily replace a rocker housing mounting bolt. These mounting bolts are located at the centre of each of the 3 rocker housing support bridges.
    • Install and tighten the 2-piece mounting stud to the rocker housing. If removing the #6 fuel injector, separate the 2-piece mounting stud. Install the lower half of the mounting stud to the center of the rocker housing bridge. Install the upper half of the mounting stud to the lower half.
    • Position the tool handle to mount the stud and install the handle nut. Leave the handle nut loose to allow a pivoting action.
    • Position the lower part of the clamshell halves to the side of the fuel injector (wider shoulder to bottom). The upper part of clamshell halves should also be positioned into the machined shoulder on the handles pivoting head.
    • Slide the retainer sleeve over the pivoting handle head to lock clamshell halves together.
    • Be sure the handle pivot nut is loose
    • Depress the handle downward to remove the fuel injector straight up from the cylinder head bore.
11. Remove and discard the injector sealing washer. This is located on the tip of the injector.

Installation

1. Inspect fuel injector:

   • Look for burrs on the injector inlet.
   • Check nozzle holes for hole erosion or plugging.
   • Inspect the end of the nozzle for burrs or rough machine marks.
   • Look for cracks at the nozzle end.
   • If any of these conditions occur, replace the injector.

2. Thoroughly clean fuel injector cylinder head bore. Blow out the borehole with compressed air.

3. The bottom of the fuel injector is sealed to the cylinder head bore with a copper sealing washer (shim) of a certain thickness. A new shim with the correct thickness must always be reinstalled after removing the injector. Shim Thickness: 1.5mm (. 060”)

4. Install a new shim (washer) to the bottom of the injector. Apply a light coating of clean engine oil to the washer. This will keep the washer in place during installation.

5. Apply a small amount of clean engine oil to the o-ring.

6. Install injector into cylinder head with male connector port facing the intake manifold. Push down on the fuel injector mounting flange to engage the o-ring and seat injector.

7. Tightening sequence:

   • Install fuel injector hold-down clamp (mounting flange) bolts. Do a preliminary tightening of these bolts to 44 in. lbs. torque. This preliminary tightening insures the fuel injector is seated and centered.
   • After tightening, relieve bolt torque, but leave both bolts threaded in place.
   • Install a high-pressure connector and retaining nut. Do a preliminary tightening to 11 ft. lbs. torque.
   • Alternately tighten the injector and hold down bolts to 89 in. lbs. torque.
   • Do a final tightening of the high-pressure connector and retaining nut.
     Tighten to 44 ft. lbs. torque.

8. Connect injector solenoid wires and nuts to the top of the injectors. Tighten connector nuts to 11 in. lbs. torque. Be very careful not to over-tighten these nuts as damage to the fuel injector will occur.

9. Install exhaust rocker arm assembly (27 ft. lbs.).

10. Set exhaust valve lash.

11. Install a high-pressure fuel line. Refer to torque specifications. Be sure to use a secondary back-up wrench on the connector nut while torquing the fuel line fitting.

12. Install valve cover.

13. Install breather assembly.

14. Connect negative battery cables to both batteries.

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