M11 Series – Service Manual – 006-026   Injector

Disconnect the battery cables before removing or installing the injectors.

Remove the air piping from the charge air cooler to the intake manifold. Remove the hose from the crankcase breather.

Remove the rocker lever cover. Refer to Procedure
003-011.

If the engine is equipped with engine brakes, the brakes
must be removed in order to remove the injectors.

Disconnect the two electrical connections from the terminals on the inside and outside of the engine brake spacer housing.

Disconnect the oil supply hose connection.

Remove the oil supply hose.

Use your fingers or a screwdriver to press the engine brake housing oil connector into the front brake housing to allow clearance for the housing removal.

Remove the 16 engine brake mounting capscrews and both engine brake housings.

Loosen the injector and valve adjusting screws and remove the push rods and push tubes on the cylinder requiring injector replacement.

Some push rods are under compression due to the valves being open. Rotate the crankshaft
clockwise with the accessory drive pulley to relieve the spring tension.

Mark the position of the push rods and push tubes as they are removed. Due to wear patterns on the cam follower sockets and adjusting screws, the push rods and push tubes
must be installed in the same positions from which they are removed.

Hold the push rod with one hand to prevent it from falling into the engine. Loosen each adjusting screw and remove the push rod.

Remove the crossheads. Mark the position and orientation of the crossheads as they are removed. Due to wear patterns, they
must be installed in the same positions from which they are removed.

Disconnect the injector wires. Number the injector electrical connections as they are removed. They
must be connected to the same cylinder when they are installed.

Remove the clamp capscrew and injector hold down clamp.

Use Injector Puler/Installer service tool, Part Number 3823579, to remove the injectors. Insert the pin of the tool into the hole provided in the body of the injector.

If an injector puller is
not available, carefully use a pry bar. Pry upward on the injector against the cylinder head.

Disconnect the battery cables before removing or installing the injectors.

Remove the air piping from the charge air cooler to the intake manifold. Remove the hose from the crankcase breather.

Remove the rocker lever cover. Refer to Procedure
003-011.

If the engine is equipped with engine brakes, the brakes
must be removed in order to remove the injectors.

Disconnect the two electrical connections from the terminals on the inside and outside of the engine brake spacer housing.

Disconnect the oil supply hose connection.

Remove the oil supply hose.

Use your fingers or a screwdriver to press the engine brake housing oil connector into the front brake housing to allow clearance for the housing removal.

Remove the 16 engine brake mounting capscrews and both engine brake housings.

Loosen the injector and valve adjusting screws and remove the push rods and push tubes on the cylinder requiring injector replacement.

Some push rods are under compression due to the valves being open. Rotate the crankshaft
clockwise with the accessory drive pulley to relieve the spring tension.

Mark the position of the push rods and push tubes as they are removed. Due to wear patterns on the cam follower sockets and adjusting screws, the push rods and push tubes
must be installed in the same positions from which they are removed.

Hold the push rod with one hand to prevent it from falling into the engine. Loosen each adjusting screw and remove the push rod.

Remove the crossheads. Mark the position and orientation of the crossheads as they are removed. Due to wear patterns, they
must be installed in the same positions from which they are removed.

Disconnect the injector wires. Number the injector electrical connections as they are removed. They
must be connected to the same cylinder when they are installed.

Remove the clamp capscrew and injector hold down clamp.

Use Injector Puller/Installer service tool, Part Number 3823579, to remove the injectors. Insert the pin of the tool into the hole provided in the body of the injector.

If an injector puller is
not available, carefully use a pry bar. Pry upward on the injector against the cylinder head.

NOTE: Calibration requires special equipment and
must be done at a Cummins Authorized Repair Location.

Every 6000 hours, clean and rebuild or replace the injectors.

To clean and calibrate the injectors, remove them from the engine. The injectors
must be calibrated on an injector test stand.

Remove the hose from the crankcase breather.

Remove the 16 capscrews, isolators, and spacers from the rocker lever cover assembly.

Remove the cover and gasket.

NOTE: Mark the position of the push rods as they are removed. Due to wear patterns on the cam follower sockets and adjusting screws, the push rods
must be installed in the same positions from which they are removed.

Loosen the locknut and turn out the adjusting screw on each injector and valve rocker lever.

Some push rods are under compression due to the valves being open. Rotate the crankshaft
clockwise with the accessory drive pulley to relieve the spring tension.

Hold the push rod with one hand to prevent it from falling into the engine. Loosen each adjusting screw and remove the push rod.

NOTE: Do
not remove the links from step timing control injectors.

Rotate the injector and valve rocker levers up on each cylinder.

Remove the crossheads. Mark the position and orientation of the crossheads as they are removed. Due to wear patterns, they
must be installed in the same positions from which they are removed.

Loosen the injector hold-down capscrew and remove the hold-down.

Use Injector Puller/Installer service tool, Part Number 3823579, to remove the injectors.

Take the injectors to a Cummins Authorized Repair Location.

CAUTION  Do not use anything metal to scrape the injector copper sleeves. Damage to the injector sleeve can occur.

Use a clean wooden stick with a clean cloth wrapped around the end to remove all of the carbon from the copper injector sleeves in the cylinder head.

CAUTION  Do not use anything metal to scrape the copper injector sleeves.

Use a clean wooden stick with a clean cloth wrapped around the end to remove all the carbon from the copper injector sleeves in the cylinder head.

Use a chip removing unit to remove the carbon from the top of the piston.

NOTE: It is important that three new o-rings be installed and oriented correctly on each injector when installing them.

Install three new o-rings on each injector. Do
not twist the o-rings.

Lubricate the o-rings with clean 15W-40 lubricating oil just before installation.

CAUTION  Do not drive the injector in by striking the solenoid valve area. This can damage the solenoid or cause the injector to be out of alignment in the bore which will result in o-ring damage.

Place the injector in the cylinder head injector bore with the injector solenoid valve toward the intake port. Align the injector equally between the valve springs.

Use Injector Puller/Installer service tool, Part Number 3823579, to seat the injector in the bore.

CAUTION  The injector must be fully seated before installing the hold down clamp. The hold down clamp can not pull the injector into the bore. Engine damage can occur if the injector is not fully seated.

Install the injector hold down clamp capscrew.

Connect the injector wires. Make sure the wires are connected to the same cylinder they were removed from.

Check the wire connector to make sure the connector is properly locked in position.

If the wire connector will
not properly lock into position, refer to the Troubleshooting and Repair Manual, CELECT™ Plus Fuel System, Bulletin
3666130.

Install the crossheads on the intake and exhaust valves.

NOTE: The crossheads
must be installed in the same positions from which they were removed.

Rotate the rocker levers down and install the push rods and push tubes.

NOTE: It is necessary to bar the engine over and install the push rods and push tubes as camshaft position allows.

Adjust the valves and injectors. Refer to Procedure
003-004.

Loosen the locknuts on the engine brake slave piston. Make sure the slave pistons are fully retracted.

Install the engine brake housing on the rear rocker lever supports.

Use clean 15W-40 oil to coat the bottom side of the capscrew heads and the threads.

Install the capscrews in the rocker lever supports. Tighten the capscrews in the sequence shown.

Install new o-rings on the brake oil connector.

Use clean 15W-40 oil to lubricate the o-rings on the oil connector.

Press the connector all the way into the front housing by hand.

NOTE: When installing the front housing, be sure the oil connector and o-ring are in position to be pushed into the rear housing.

Install the front engine brake housing on the front rocker lever supports.

Center the oil connector between the front and rear housings before tightening the capscrews.

Use clean 15W-40 oil to coat the bottom side of the capscrew heads and the threads.

Install the capscrews in the rocker lever supports.

Tighten the capscrews in the sequence shown.

Adjust the engine brakes.

Install and tighten the oil supply hose fitting to the front brake housing.

Install the engine brake terminal electrical leads on the outside of the spacer.

Connect the two solenoid electrical wires to the terminals on the inside of the spacer.

Install the rocker housing cover.

Install the 16 isolators and capscrews. Tighten the capscrews in the sequence shown.

Install the crankcase breather tube. Install the air piping from the charge air cooler to the intake manifold. Refer to the manufacturer’s specifications for the correct hose clamp torque value.

Connect the battery cables.

CAUTION  Do not use anything metal to scrape the copper injector sleeves.

Use a clean wooden stick with a clean cloth wrapped around the end to remove all the carbon from the copper injector sleeves in the cylinder head.

Use a chip removing unit to remove the carbon from the top of the piston.

NOTE: It is important that three new o-rings be installed and oriented correctly on each injector when installing them.

Install three new o-rings on each injector. Do
not twist the o-rings.

Lubricate the o-rings with clean 15W-40 lubricating oil just before installation.

CAUTION  Do not drive the injector in by striking the solenoid valve area. This can damage the solenoid or cause the injector to be out of alignment in the bore which will result in o-ring damage.

Place the injector in the cylinder head injector bore with the injector solenoid valve toward the intake port. Align the injector equally between the valve springs.

Use Injector Puller/Installer service tool, Part Number 3823579, to seat the injector in the bore.

CAUTION  The injector must be fully seated before installing the hold down clamp. The hold down clamp can not pull the injector into the bore. Engine damage can occur if the injector is not fully seated.

Install the injector hold down clamp capscrew.

Connect the injector wires. Make sure the wires are connected to the same cylinder they were removed from.

Check the wire connector to make sure the connector is properly locked in position.

If the wire connector will
not properly lock into position, refer to the Troubleshooting and Repair Manual, CELECT™ Plus Fuel System, Bulletin
3666130.

Install the crossheads on the intake and exhaust valves.

NOTE: The crossheads
must be installed in the same positions from which they were removed.

Rotate the rocker levers down and install the push rods and push tubes.

NOTE: It is necessary to bar the engine over and install the push rods and push tubes as camshaft position allows.

Adjust the valves and injectors. Refer to Procedure
003-004.

Loosen the locknuts on the engine brake slave piston. Make sure the slave pistons are fully retracted.

Install the engine brake housing on the rear rocker lever supports.

Use clean 15W-40 oil to coat the bottom side of the capscrew heads and the threads.

Install the capscrews in the rocker lever supports. Tighten the capscrews in the sequence shown.

Install new o-rings on the brake oil connector.

Use clean 15W-40 oil to lubricate the o-rings on the oil connector.

Press the connector all the way into the front housing by hand.

NOTE: When installing the front housing, be sure the oil connector and o-ring are in position to be pushed into the rear housing.

Install the front engine brake housing on the front rocker lever supports.

Center the oil connector between the front and rear housings before tightening the capscrews.

Use clean 15W-40 oil to coat the bottom side of the capscrew heads and the threads.

Install the capscrews in the rocker lever supports.

Tighten the capscrews in the sequence shown.

Adjust the engine brakes.

Install and tighten the oil supply hose fitting to the front brake housing.

Install the engine brake terminal electrical leads on the outside of the spacer.

Connect the two solenoid electrical wires to the terminals on the inside of the spacer.

Install the rocker housing cover.

Install the 16 isolators and capscrews. Tighten the capscrews in the sequence shown.

Install the crankcase breather tube. Install the air piping from the charge air cooler to the intake manifold. Refer to the manufacturer’s specifications for the correct hose clamp torque value.

Connect the battery cables.

Install a set of new injectors using the 8-qt 10-hole cup configuration that was removed from the engine. This will make sure that the injectors will
not have any unseen cavitation damage internal to the injector cup at the time of kit installation.

Install three new o-rings over the injector and into the retaining grooves. Do
not twist the o-rings.

Lubricate the o-rings with clean engine oil just before installation.

Check the bores in the cylinder head for burrs or sharp edges that can damage the o-rings. Repair damaged injector bores.

Install new o-rings on the step timing control oil manifold connections.

Align the injector with the oil manifold connections and install the injector into the cylinder head injector bore.

CAUTION  Make sure to place the instrument used to install the injectors on the top cap of the injector, not on the plunger or link. The plungers will be damaged.

Install a 27-mm [1-1/16-in] deep well socket over the top link of the injector. The socket
must rest completely on the top surface of the injector top cap to avoid bending the inner part of the top cap.

Use a clean, blunt instrument to seat the injector in the bore.

A snap will be heard and felt as the injector is seated.

If the injector does
not seat, remove it and check the o-rings for damage. Replace damaged o-rings.

CAUTION  The injector must be fully seated before installing the hold-down clamp. The hold-down clamp can not pull the injector into the bore. Engine damage can occur if the injector is not fully seated.

Install the injector hold-down clamp and capscrew.

Install the crossheads on the valves.

NOTE: The crossheads
must be installed in the same positions from which they were removed.

Rotate the rocker levers down, and install the push rods and push tubes.

NOTE: It is necessary to bar the engine over and install the push rods and push tubes as camshaft position allows.

Make sure the push rods are properly seated in the cam follower sockets.

Turn the adjusting screw for each rocker lever in until it is properly seated in the push rod socket.

Adjust valves and injectors. Refer to Procedure
003-004.

Inspect the rocker lever cover gasket for cuts or other damage.

If necessary, install a new gasket.

Install the rocker lever cover.

Install the 16 isolators and capscrews.

Tighten the capscrews in the sequence shown.