Cummins ISX11.9 CM2250 – Service Manual 011-051   Aftertreatment Injector Lines

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

• Drain the cooling system. Refer to Procedure 008-018 in Section 8.

WARNING  If fuel lines contain pressure, there may be sufficient pressure to penetrate the skin and can cause serious injury by penetrating the skin.

Disconnect the aftertreatment fuel shutoff manifold supply line from the fuel filter head.

Disconnect the aftertreatment fuel shutoff manifold supply line at the inlet to the aftertreatment fuel shutoff manifold.

Remove the aftertreatment fuel shutoff manifold supply line and discard the banjo sealing washers.

WARNING  If fuel lines contain pressure, there may be sufficient pressure to penetrate the skin and can cause serious injury by penetrating the skin.

Disconnect the aftertreatment injector fuel supply line at the outlet of the fuel shutoff manifold.

Disconnect the fuel line p-clip from the fuel drain manifold.

Disconnect the two p-clips at the rear of the engine.

Disconnect the p-clip from the OEM coolant manifold.

Disconnect the aftertreatment injector fuel supply line at the inlet to the aftertreatment injector.

Remove the aftertreatment injector fuel supply line and discard the banjo sealing washers.

Disconnect the aftertreatment injector coolant supply line at the inlet to the aftertreatment injector.

Disconnect the aftertreatment injector coolant supply line at the engine block.

Remove the aftertreatment injector coolant supply line.

Disconnect the aftertreatment injector coolant return line at the aftertreatment injector.

Remove the aftertreatment coolant return line and discard the banjo sealing washers.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacture’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Clean the aftertreatment injector coolant lines with a safety solvent.

Inspect the aftertreatment injector coolant line threads and banjo fittings for damage. Replace if necessary.

Make sure the aftertreatment injector coolant lines are clear of debris.

Use compressed air to flush the lines and remove any loose dirt particles.

Check the o-ring for cuts and wear. Replace if necessary.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacture’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

Clean the aftertreatment injector fuel lines with a safety solvent.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Inspect the threads and banjo fittings on the aftertreatment injector fuel lines. Replace if necessary.

Make sure that the aftertreatment injector fuel lines are clear of debris.

Use compressed air to flush the lines and remove any loose dirt particles.

Inspect the face of the banjo connection for sealing surface damage.

Inspect the straight thread fittings and fuel lines for cracks, bends, or other damage.

Replace as necessary.

Install new banjo sealing washers.

Use new banjo sealing washers and install the aftertreatment coolant return line.

Connect the aftertreatment injector coolant return line to the aftertreatment injector.

Tighten the banjo bolts.

Install the aftertreatment injector coolant supply line.

Connect the aftertreatment injector coolant supply line to the inlet of the aftertreatment injector.

Connect the aftertreatment injector coolant supply line to the engine block.

Tighten both ends.

Use new banjo sealing washers and install the aftertreatment injector fuel supply line.

Connect the aftertreatment injector fuel supply line to the inlet to the aftertreatment injector.

Connect the p-clip to the OEM coolant manifold.

Connect the two p-clips to the rear of the engine.

Connect the fuel line p-clip to the fuel drain manifold.

Connect the aftertreatment injector fuel supply line to the outlet of the fuel shutoff manifold.

Use new banjo sealing washers and install the aftertreatment fuel shutoff manifold supply line.

Connect the aftertreatment fuel shutoff manifold supply line to the inlet of the aftertreatment fuel shutoff manifold.

Connect the aftertreatment fuel shutoff manifold supply line to the fuel filter head.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Operate the engine and check for leaks.