Injector install how to:

[gigabrock]

awsome right up i feel a little more confident in doing this new but how do you change the nozzles are they an actual part of the injector if so how do you change them or is there a write up about it like this one because i am seriously considering 40hp nozzles for mine just for fuel economy and a little more power and smoke

[SOUTHERN SMOKE]

Originally Posted by gigabrock

awsome right up i feel a little more confident in doing this new but how do you change the nozzles are they an actual part of the injector if so how do you change them or is there a write up about it like this one because i am seriously considering 40hp nozzles for mine just for fuel economy and a little more power and smoke

nozzles are on the end of the injector bodies, you can get them off with a socket, just be careful doing so, as to not damage the injector body, of stock nozzle if you decide to re-use them. i recommend getting the nozzle tool to remove them, but most will do it with a socket.

[Giddyup5.9]

Originally Posted by gigabrock

awsome right up i feel a little more confident in doing this new but how do you change the nozzles are they an actual part of the injector if so how do you change them or is there a write up about it like this one because i am seriously considering 40hp nozzles for mine just for fuel economy and a little more power and smoke

Make sure you have a 0-100 inch lb torque wrench and a 0-100 foot lbs torque wrench..Here are a few pics from my nozzle swap.. its pretty simple, just remember to keep things CLEAN! I used about 5 cans of brake cleaner wich is recommended on these parts and will not cause any harm.

Following the prior proceedure, remove the cover


Things are kind of tight in the truck, so take your time especially on #5 and #6, since they are underneath the cowl, tape off the intake hole so no debris fall in the hole

Keep your parts organized and separated per cylinder they came off of

Once you have removed the map sensor and taped off the hole, removed the injector rail lines, removed the connector tube nuts and tube, valve cover gasket and injector wirinng, exhaust rocker and elephants foot, pry the injector out carefully and place the injector in the holding plate that comes in your kit..Clean the injector thouroughly! You cannot afford to have any small debris lingering when you pull the tip off so cleanlyness is a must

Remove the copper gasket that comes out with each injector, make sure you get all 6 so you dont leave one in the head and replace with a new gasket!

Be carefull and take the tip apart. I used a box end wrench since I didnt have a deep socket, plus it gives you a visual on the tip so you dont damage anything, they are torqued to 50ftlbs so it will be kind of a pain to bust apart

The end piece threads off, simply hold your finger on the end of the tip and thread the injector apart and carefully remove the cap. There are 2 little pins on the end that extrude out to line the tip up properly, also there is a little piece in the middle.. dont lose any of these! Your stock tips are going to be dirty so again be giving on the brake cleaner, once you have the tip off, take your finger and hold the little pieces in place and spray around them to clean the area thouroughly...dont let the peices blow out! I lucked out and found a piece that blew out of mine.. im sure they arnt readily available so just take your time and work slow/clean. Mark a special place to put the used tips and install the new ones after confirming that all 6 have the same part # in your new kit, repeat the process in reverse and re-torque the cap to 50ftlbs, some say 55ftlbs.. either will work


Reinstall the injector and re-torque as per the preceedure, reinstall the elephants foot and rocker arm after cleaning and install the rocker bolt and torque up in levels.. I did 10-15-27ftlbs becuase I actually snapped #5 rocker bolt at less then 27ftlbs.. These are grade 12.9 bolts so I cannot explain why it broke but its better that it broke now then once the motor was running. New bolts are available for $3.00 a piece through dodge or you can do like I did and replace it with another 12.9 grade bolt i got from fastenall for $1.99. There isnt a need to set valve lash since the rockers are already adjusted per the adjuster on the arm, just make sure to keep them with the cylender then came off of. Spray out the fuel rail good and clean, and do the same to the injector lines... the smallest bit of debris will cause the injector to fail.. follow the torque specs to a T and just keep clean, work slow and enjoy the fact that you can now do your own injectors without having to go to the dealer!

[jjpage]

This was done by sag2 on TDR!
Injector install procedure with photos - TDR Roundtable

[TEX]

ok 1st thanks
2nd i can understand the bud light and shiner but........
3rd the right guard?? guess you were tryin to "keep everything clean" and smellin fresh LOL

thanks again bud

[Laramie4x4]

whered the soup come into play!!!!!

[DODGE74]

Originally Posted by Laramie4x4

whered the soup come into play!!!!!

I was thinking the same thing! Plus its half opened. He must of been drinking his soup eating his beer and putting Right Gaurd on his parts.

[abadcat]

Great write up

[Giddyup5.9]

Originally Posted by jjpage

This was done by sag2 on TDR!
Injector install procedure with photos - TDR Roundtable

Its actually available a few places around here, I actually had it on a .pdf format on my desktop that someone made downloadable aparantly from sag2's post but I didnt know that sag had that post out there untill recently or i wouldnt have taken the time to copy and paste all the info on here from the .pdf format.. either way thats why on the first page I say

''Ive noticed a few threads about injector talk/specs/install and removal. I figured I would help everyone out and post this up as a quick guide for everything. This has helped me and hopefully can help you. Enjoy.''

plus not everyone is a member of tdr

Originally Posted by TEX

ok 1st thanks
2nd i can understand the bud light and shiner but........
3rd the right guard?? guess you were tryin to "keep everything clean" and smellin fresh LOL

thanks again bud

uhhh.... It was a long night lol

Originally Posted by Laramie4x4

whered the soup come into play!!!!!

Originally Posted by DODGE74

I was thinking the same thing! Plus its half opened. He must of been drinking his soup eating his beer and putting Right Gaurd on his parts.

well honestly.. I was hungry! and its pork and beans

this was an overnight project for me since the #5 bolt broke, it took me about 7 hours to get it out of the head with a long 90 degree drill extension and a left handed bit.. honestly I was ready to pull the head and be in it for the long haul!

I actually made a video pulling the injector apart but at that point when i decided to make a video i was a little.. 'happy' lol, i wouldnt dare posting it up after watching it the next day

[Laramie4x4]

hahahahahahahahaha very funny

[Giddyup5.9]

Originally Posted by Laramie4x4

hahahahahahahahaha very funny

Oh it was definatly a hell of a night.. I was on the phone with kenny like dude.... wtf lol

how many times in your life are you going to have to use this, a mirror and 3 magnets to work on a cummins

[Laramie4x4]

I know that feeling..Kenny called me at 12pm asking me if I know how to weld exhaust... when he lost it a few weeks ago!!!!