Owners manual

ManualsBrandsBD Diesel ManualsAutomotive1040175 Fuel Injector Kit

Kit# 1040175 / 1040210 / 1040220 / 1040275

June 2004 - 1 -

INJECTION PERFORMANCE

MODIFICATION

CUMMINS 6BTA5.9

FUEL INJECTORS:

REMOVAL:

1: Disconnect both negative battery cables from both

batteries.

2: Remove the high-pressure fuel lines. See High

Pressure Fuel Line removal & installation.

3: Remove the fuel drain manifold. See Fuel Drain

Manifold removal & installation.

4: Thoroughly clean the area around the injector.

Caution: When rust has formed on the fuel injector

nut, (Fig 1) the injector (when being removed) can

rotate in the cylinder head. This may cause damage

to the cylinder head bore. Use a rust penetrating

solvent before attempting to loosen a rusted hold-

down nut.

5. Hit the injector body with a brass drift to loosen it.

(Fig. 2)

6: Hold the injector body with one wrench while

removing the injector nut with another. (Fig. 3)

7: It may be necessary to tap the injector with an

injector puller tool. (Fig 4)

BD Engine Brake Inc.

Fig 1: Loosening Injector Nut

Fig 2: Loosening Injector Body

Fig 3: Loosening injector

Fig 4: Removing Injector with Puller Tool

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: PO Box 231, Sumas, WA 98295

Phone: (604) 853-6096 Fax: (604) 853-8749 Internet: www.bd-power.com

Summary of content (6 pages)

PAGE 1
June 2004 Kit# 1040175 / 1040210 / 1040220 / 1040275 -1- INJECTION PERFORMANCE MODIFICATION TO CUMMINS 6BTA5.9 FUEL INJECTORS: REMOVAL: 1: Disconnect both negative battery cables from both batteries. 2: Remove the high-pressure fuel lines. See High Pressure Fuel Line removal & installation. 3: Remove the fuel drain manifold. See Fuel Drain Manifold removal & installation. Fig 2: Loosening Injector Body 4: Thoroughly clean the area around the injector.
PAGE 2
June 2004 Kit# 1040175 / 1040210 / 1040220 / 1040275 -2- *** PLEASE NOTE *** TIP WASHERS FOR INJECTORS Two different thicknesses of injector tip washers have been included in this kit. When installing the new injector washers, (re: figure #6) select the injector washers that are the same thickness as the used washers from the old injectors.
PAGE 3
Kit# 1040175 / 1040210 / 1040220 / 1040275 June 2004 -3- INSTALLATION: 1: Clean the injector cylinder head bore with special Cummins wire brush tool or equivalent (Fig. 5) 4: Install the injector into the cylinder head. Align the tab on the injector to the notch in the cylinder bore (Fig 8). Certain types of injectors may have an o-ring located above the hold-down nut (Fig 8). After tightening the injector, push the o-ring into the groove the top of the injector.
PAGE 4
June 2004 Kit# 1040175 / 1040210 / 1040220 / 1040275 REMOVAL: 1: Disconnect both negative battery cables from both batteries. 2: Remove the nameplate/cover from the top of the six engine valve covers (two nuts) (Fig 9) -4- Caution: Be sure that the high-pressure fuel lines are installed in the same order that they were removed. Prevent the injection pump delivery valve holders from turning when removing or installing high-pressure lines from injection pump.
PAGE 5
June 2004 Kit# 1040175 / 1040210 / 1040220 / 1040275 -5- FUEL DRAIN MANIFOLD REMOVAL: 1: Remove the two nuts retaining the nameplate/cover to the top of the six engine valve covers (Fig 12). Remove nameplate cover from the engine.
PAGE 6
BD ENGINE BRAKE DISCLAIMER OF LIABILITY Other than as expressly set forth herein, BD ENGINE BRAKE, Inc. (hereafter collectively, "SELLER"), together with its distributors, jobbers and dealers shall in no way be responsible for the PRODUCT’S proper use and service.