Cummins ISX11.9 CM2250 – Service Manual 011-061   Aftertreatment Fuel Injector Coolant Test

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

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.

NOTE: Determine the appropriate radiator or coolant expansion tank cap adapter for the vehicle being serviced. A list of available caps and applications can be found in Section 14 of the Service Products Catalog, Bulletin 3377710.

Use a vacuum pump type device on the cooling system. Install the adapter on the radiator or coolant expansion tank. Connect an automotive hand held vacuum pump and apply 3 in Hg [40 in H₂O] of vacuum.

NOTE: Depending on the cooling system configuration, more vacuum may be required to keep the cooling system in balance.

Place a container under the aftertreatment fuel injector. There may be a small quantity of coolant that drains from the coolant lines when disconnected.

• Disconnect the fuel line to the aftertreatment fuel injector. Refer to Procedure 011-051 in Section 11.
• Discard the fibrous insulator.
• Discard the metal gasket.
• Discard the capscrews.
• Disconnect the coolant lines to the aftertreatment fuel injector. Refer to Procedure 011-051 in Section 11.
• Remove the aftertreatment fuel injector from the exhaust adapter pipe. Refer to Procedure 011-042 in Section 11.

Plug one of the coolant connections with an M16 x 1.5 plug.

Fill the nozzle area with water.

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

Apply compressed air regulated at 241 kpa [35 psi] to the opposite coolant connection.

If air bubbles are seen in the nozzle area, the aftertreatment injector has a crack that is allowing coolant to leak through.

The injector must be replaced.

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

• Remove the plug and compressed air connection from the coolant connection points.
• Install a new fibrous insulator.
• Install a new metal gasket.
• Install the aftertreatment fuel injector assembly onto the adapter pipe. Refer to Procedure 011-042 in Section 11.
• Connect the fuel line to the aftertreatment fuel injector. Refer to Procedure 011-051 in Section 11.
• Connect the coolant lines to the aftertreatment fuel injector. Refer to Procedure 011-051 in Section 11.
• Connect the wiring harness to the aftertreatment injector.
• Remove the vacuum pump.
• Start the engine, check for leaks, and verify all fault codes are inactive.