FUEL INJECTOR REMOVAL AND INSTALLATION
2003-2007 CUMMINS 5.9L

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 mounted into 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 ends of
cables.
(2) Remove breather assembly.
(3) Remove valve cover.
(4) Remove high-pressure fuel line connecting fuel injector rail to high-pressure
connector.
(5) A connector retainer nut is used on each connector tube. Remove this by
unthreading from cylinder head.
(6) Using special high-pressure connector removal tool #9015 (recommended by
Cummins), remove necessary high-pressure connectors from cylinder head. Tool
#9015 threads onto connector tube. Use tool to pry connector tube from 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 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.
b- 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 center of each of the 3
rocker housing support bridges.
c- Install and tighten 2-piece mounting stud to rocker housing. If removing the
#6 fuel injector, separate the 2-piece mounting stud. Install lower half of
mounting stud to center of rocker housing bridge. Install upper half of mounting
stud to lower half.
d- Position tool handle to mounting stud and install handle nut. Leave handle
nut loose to allow a pivoting action.
e- Position lower part of clamshell halves to side of fuel injector (wider
shoulder to bottom). The upper part of clamshell halves should also be
positioned into machined shoulder on the handles pivoting head.
f. Slide the retainer sleeve over the pivoting handle head to lock clamshell
halves together.
g- Be sure handle pivot nut is loose
h. Depress handle downward to remove fuel injector straight up from cylinder
head bore.
(11) Remove and discard injector sealing washer. This is located on tip of injector.
Installation
(1) Inspect fuel injector:
a. Look for burrs on injector inlet.
b. Check nozzle holes for hole erosion or plugging.
c. Inspect end of nozzle for burrs or rough machine marks.
d. Look for cracks at nozzle end.
e. If any of these conditions occur, replace injector.
(2) Thoroughly clean fuel injector cylinder head bore. Blow out bore hole 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 a correct thickness
must always be reinstalled after removing injector. Shim Thickness: 1.5mm (.
060”)
(4) Install new shim (washer) to bottom of injector. Apply light coating of clean
engine oil to washer. This will keep washer in place during installation.
(5) Install new o-ring to fuel injector. Apply small amount of clean engine oil to oring.
(6) Install injector into cylinder head with male connector port facing the intake
manifold. Push down on fuel injector mounting flange to engage o-ring and seat
injector.
(7) Tightening sequence:
a. 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.
b. After tightening, relieve bolt torque, but leave both bolts threaded in place.
c. Install high-pressure connector and retaining nut. Do a preliminary
tightening to 11 ft. lbs. torque.
d. Alternately tighten injector hold down bolts to 89 in. lbs. torque.
e. 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 top of injectors. Tighten connector
nuts to 11 in. lbs. torque. Be very careful not to over tighten these nuts as
damage to fuel injector will occur.
(9) Install exhaust rocker arm assembly (27 ft. lbs.).
(10) Set exhaust valve lash.
(11) Install high-pressure fuel line. Refer to torque specifications. Be sure to use a
secondary back-up wrench on the connector nut while torquing fuel line
fitting.
(12) Install valve cover.
(13) Install breather assembly.
(14) Connect negative battery cables to both batteries.

Stanadyne Diesel Systems for Generators

SPEED DROOP ADJUSTMENT DURING ENGINE

1) After priming fuel system, start and warm engine to operating temperature.

2) With full load applied and engine operating at rated speed, droop may be determined by removing load and noting no-load speed or frequency Droop may be adjusted by turning knurled knob clockwise to increase, counter clockwise to decrease.

3) A minor correction of throttle position will also be necessary.

NOTE: If knurled knob is adjusted to maximum or near maximum droop, severe strain will be placed on the throttle and governor linkage parts unless the throttle cable or linkage is first disconnected from the pump throttle lever After final droop setting, throttle linkage length may be readjusted and reinstalled on the pump throttle lever This precaution is not necessary if a spring-loaded throttle lever is incorporated.

Delco Diesel Dodge Pump Relay Kit

1. Mount the fuel pump relay on the firewall with the supplied self tapping screw.
2. Attach the ground (black wire) with either a self tapping screw or to a suitable ground.
3. Attach the Red (orange) wire to the positive side of the battery.
4. Route the lead wire over the brake master cylinder and secure with a zip tie out of the way of the steering knuckle.
5. Disconnect the lift pump from the factory wiring harness and reconnect to the relay plugs.
6. Test the lift pump by turning the ignition to the start position and then “bump” the starter, that is do not hold the key on unit the engine starts, but just long enough to engage the starter and wait to start the engine. The lift pump should then be energized to 20 to 25 seconds.

The purpose of this Relay Kit is to provide a more consistent 12 volt power supply to the fuel pump. It is not designed to make an already damaged pump work. It will not allow a voltage drop to the supply pump and will therefore extend fuel pump life and maintain better pressure and flow.