Injector install how to: - Dodge Cummins Diesel Forum
- HOME - FORUMS - GARAGE - TECH - ARTICLES - CHAT - CLASSIFIEDS - REVIEWS - VIDEOS - MEMBER MAP - STORE - INSURANCE -
- REGISTER - CALENDAR - INFO - SITE HELP - RULES - STAFF - MEMBERSHIP - ADVERTISE - CONTACT US -


Welcome to the Dodge Cummins Diesel Forum, the fastest growing Dodge Diesel Community on the internet.

You are currently viewing our boards as a guest which gives you limited access to view most discussions and access our other features. By joining our free community you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is fast, simple and absolutely free so please, join our community today!

If you have any problems with the registration process or your account login, please contact contact us
Go Back   Dodge Cummins Diesel Forum > 3rd Gen. Dodge Cummins 03-07 Common Rail Forums > 3rd Gen. Performance Parts Discussion
3rd Gen. Performance Parts Discussion Discussion of Performance Parts For the 3rd Gen Trucks No Advertising ...NO ADVERTISING

CumminsForum.com is the premier Dodge Diesel Truck Forum on the internet. Registered Users do not see the above ads.

» Auto Insurance

» Featured Product
» Wheel & Tire Center

Reply
 
LinkBack Thread Tools Display Modes
Old 10-03-2009, 02:38 AM   #1 (permalink)
CF Administrator
 
THE STIG's Avatar
 
Join Date: Nov 2008
Location: Utah - S. Texas
Posts: 11,893
Thanks: 1,271
Thanked 4,148 Times in 2,009 Posts
iTrader Score: 6 reviews
Injector install how to:

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.


This is intended to assist you with an injector change to make it more visual along with the
factory service manual. Please follow all directions and cautions in the factory service manual.
One caution in the manual is that all injectors look the same, but are not necessarily
interchangeable. Be sure you know what you are installing if not making a direct factory
replacement. Also note all cautions working around high pressure fuel systems. Also note the
photos and directions are taken from an 04 engine and the 04 factory service manual, and
might be different from the truck you are working on. Use the appropriate adjustment specs
from the proper year manual. Note that 2006 exhaust valve setting is different from 03-05.
One final note, in addition to the special tools noted, this job can not be done without a quality
inch pound and foot pound torque wrench which were not shown in the photos. Although the
procedure shown used all the factory supplied special tools, the job can be completed without
them if need be. That being said, when the injectors are $400+ each, the investment in the
tools is probably a good idea. All of the special tools can be purchased at Miller special tool, an
SPX company.
The following hand tools are required.
24mm or 15/16 end wrench
19mm end wrench
24mm or 15/16 socket
8mm, 10mm socket
T15 Torx driver
Screw driver
Inch pound torque wrench
Foot pound torque wrench
Some gaskets might be required, so read the entire procedure in the service manual so you
know what gaskets they recommend replacing. From my experience, most of the seals can be
used many times as long as they are not damaged. I would suggest you have the seals and
gaskets on hand unless you can obtain them obtain them quickly. Also see if they are
returnable to the dealer if you do not need them. The valve cover gasket should almost never
need to be replaced if it was not leaking before you removed it.

Disconnect both battery cables
Remove 10mm bolts that hold intake, heater grid, dipstick, and wiring.
Remove 11mm Intercooler boot clamp.


Remove 10mm bolts on plastic valve cover, cover.
Remove hoses from breather box.
Remove 10mm bolts holding upper valve cover.
*Note that there are rubber O-ring seals on the valve cover bolts


Disconnect 19mm high pressure lines from injector connector tubes.
Loosen 13mm bolts on back of head that hold bracket just behind last injector line.
Remove 13mm bolt from rear fuel line holder. (04.5 and up only)
Remove 10mm fuel line hold down brackets.
Remove 15mm rear engine lift bracket bolts and bracket.
Remove map sensor from intake with T15 torx.
Remove 24mm nuts holding high pressure connector tubes.

Using Miller 9015 connector tube puller, thread the tool into the connector tube and pry/pull
the tube straight out. The nut is still in place in the photo, but obviously needs to be removed
first. If you don’t have the 9015, you really risk damaging the connector tube threads if the
tube sticks in the head.

Remove 10mm bolts holding exhaust rocker arms, these are in the middle of the rocker, and
sometimes covered in oil. Make sure to keep track of which cylinder these came from.
Remove 8mm injector wires.
Remove 8mm injector hold down bolts.

Using Miller 9010, assemble tool per the service manual procedure and pull the injector up and
out of the bore


If you do not have the special tool, be very careful as you pry the injector out by prying on
each side of the hold down a little at a time

Inspect the injector and connector tube end for any damage as detailed in the service manual.
Remove and discard the copper seal ring (be sure it did not stay in the bore) and clean the tip
of any carbon with clean diesel fuel and a soft brush. The connector tube crushes into a hole in
the injector to seal the tube. There can not be any deformation of the connector tube, or it will
not seal properly. Also the connector tube has an edge filter built into it that breaks up small
particles of debris into particles that will not harm the injector. I always tap the tube on a
piece of white paper to dislodge and inspect for any debris. Also look at the tube for any
corrosion from contaminates in the fuel.

Clean the injector bore in the head and blow it out.


These are the parts removed from the head

If everything has been inspected/cleaned/replaced, it is time to reinstall the injector. Replace
the O-ring on the injector and lube it with some engine oil. Replace the copper seal ring with
the appropriate thickness (as directed in service manual) and put a dab of oil on it to keep it
on the injector as you install. The injector is installed with the hole facing the intake manifold.
The retainer is pinned on the injector to hold it in the proper orientation to the connector tube.
Ensure that the injector “clicks” into place. If using the special Miller tool 9010, install the
supplied nut to the top of the threaded bolt to change its use to an installing tool, allowing you
to use the lever to pry the injector into the bore without damaging it.
Tighten the injector carefully following the service manual. From the 04 service manual,
torque the injector bolts to 44 inch pounds, then back off the bolts.

Install the connector tube with the balls facing up. The balls will go into a slot in the head, and
keep the tube from rotating in the head when you loosen/tighten the nut. Ensure that the
connector tube “clicks” into place.

Tighten the connector tube to 11 foot pounds. This is the step most technicians’ short cut by
using a box end wrench to tighten the connector tube. By not correctly installing the tube, you
risk leaks internal to the engine that can cause hard starting, stalling, and rough running etc.

Tighten the injector hold down bolts alternately to 89 inch pounds. Then tighten the connector
tube to 37 foot pounds. Tighten the injector wire connector nuts to 11 inch pounds. Be very
careful to not over tighten.
Install the rocker arm (the elephant foot that connects the two exhaust valves can go on
either way) and torque to 27 foot pounds. Make sure the pushrod is properly seated into the
lifter. Set the valve lash per the service manual.
Install the fuel lines (be careful not to bend the lines) and tighten using a back up wrench on
the connector tube nut. Torque the fuel line fittings to 22 foot pounds. Install fuel line hold
down brackets and torque to 18 foot pounds. Reinstall map sensor.

Reinstall safety bracket behind the #6 injector. This is a bracket designed to keep the
occupants safe from fuel in a crash. Do not discard!
Install upper valve cover, and torque to 18ft lbs.
Reinstall intake, and tighten to 18ft lbs.
Retighten intercooler boot.
Reinstall dip stick, and wiring onto intake.
Reinstall valve cover, cover.
Reconnect negative battery cables, and start truck. There will be some smoke at startup that
should go away within 30 seconds or so. If the truck does not start check connector tube
torque. Under no circumstances should the high pressure fuel lines be loosened to bleed. The
system is self bleeding. You can be maimed or killed.
__________________
Powerful - Reliable - Inexpensive. Pick any two at a time, the third is not included.


Some men are born great, some achieve greatness and some get it as a graduation gift. - Robin Williams


THE STIG is offline   Reply With Quote Quick reply to this message
The Following 42 Users Say Thank You to THE STIG For This Useful Post:
1eric1 (03-12-2010), B Grubbie (03-04-2010), BigBusa (01-13-2010), BigJohnston (11-08-2009), Boomhower06 (11-19-2013), cflaherty (11-25-2012), chovanl (11-26-2012), commtrd (10-29-2013), cudamills (03-31-2011), cummins04 (11-08-2009), DarkHorse (03-17-2013), DieselTim27 (11-26-2012), DodgeMech (08-19-2010), drew03 (05-05-2011), Fisherguy (10-18-2014), fouled_up (01-18-2010), Fueledbyhaters (10-19-2014), Goslin32 (01-17-2010), hondaracer408 (11-08-2009), Hookdriver (10-29-2014), j-miller (11-14-2014), kaiserbailey (04-08-2010), L_GUNN (03-04-2010), mallen3831 (02-08-2011), Midnight Smoker (12-05-2012), motocraneguy17 (11-08-2009), motoman006 (12-08-2009), N1NJ4ON3R (02-17-2014), nape (01-10-2012), PAridgerunner (12-04-2009), RiotAct (10-19-2010), Rmccarthy159 (03-07-2013), SOUTHERN SMOKE (11-08-2009), Stew Pudasoe (11-16-2012), Str8_Addiction (12-05-2012), Sur5er (09-19-2014), TEX (11-08-2009), tgibbs (06-01-2010), Timecode (12-03-2009), uc_bearcat_cummins (05-05-2013), w5gm (11-16-2010), Weldittoit (03-05-2011)
Sponsored Links
Advertisement
 
Old 10-03-2009, 02:49 AM   #2 (permalink)
Diesel Head
 
BILLS06's Avatar
 
Join Date: Nov 2007
Location: Baker, MT
Posts: 1,823
Thanks: 23
Thanked 119 Times in 89 Posts
iTrader Score: 3 reviews
A clean engine is essential to. Dirt can wreck the fuel injection system.
__________________
06 QCSB SLT
Headlight Eyelids Fluidampr EZ Down ATS Converter Fog Lamps Aero Turbine Muffler Reflex Bed Liner

[SIGPIC][/SIGPIC]
BILLS06 is offline   Reply With Quote Quick reply to this message
Old 10-03-2009, 02:50 AM   #3 (permalink)
Diesel Head
 
Black03cummins's Avatar
 
Join Date: Oct 2007
Location: Gillette, WY
Posts: 2,661
Thanks: 196
Thanked 329 Times in 263 Posts
iTrader Score: 11 reviews
nice job!!!!!!
__________________
03 Fass 150, Floor-it Stage 2, Flux 2.5, Hamilton 110 Springs & Pushrods, Spool Aid, ATS ArcFlow, ATS Subzero IC, ATS Stage 4 Tranny, HE351/Aurora 6K, Doghouse Diesel 1-piece Driveline, 7 Autometer Phatom, H11 Headstuds, Pinnacle Exhaust, Wicked Bypass, Smarty Touch, Smarty UDC by Coffman Customs Soon: 62/65/12, GDP Ladder Bars, and Billet Output

My Build
http://www.cumminsforum.com/forum/3r...tle-build.html
Black03cummins is offline   Reply With Quote Quick reply to this message
Old 10-03-2009, 11:00 PM   #4 (permalink)
CF Administrator
 
THE STIG's Avatar
 
Join Date: Nov 2008
Location: Utah - S. Texas
Posts: 11,893
Thanks: 1,271
Thanked 4,148 Times in 2,009 Posts
iTrader Score: 6 reviews
Quote:
Originally Posted by BILLS06 View Post
A clean engine is essential to. Dirt can wreck the fuel injection system.
yeahhhhhhhhhhhh i dont think everyone will be doing this proceedure with a new engine on a stand


NOZZLE REMOVAL!


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!



:thumbsup
__________________
Powerful - Reliable - Inexpensive. Pick any two at a time, the third is not included.


Some men are born great, some achieve greatness and some get it as a graduation gift. - Robin Williams



Last edited by THE STIG; 08-21-2010 at 07:48 PM.
THE STIG is offline   Reply With Quote Quick reply to this message
The Following 6 Users Say Thank You to THE STIG For This Useful Post:
cudamills (03-31-2011), DieselTim27 (11-26-2012), Hookdriver (10-29-2014), N1NJ4ON3R (02-17-2014), Rmccarthy159 (03-07-2013), Rudyson (03-16-2012)
Old 10-03-2009, 11:11 PM   #5 (permalink)
BC Chapter President
 
Fisherguy's Avatar
 
Join Date: Jan 2007
Location: Near Vancouver, BC, CANADA
Posts: 5,378
Thanks: 262
Thanked 370 Times in 331 Posts
iTrader Score: 0 reviews
Great write up for do it yourselfers like most of us on here.
__________________
06 QC 3500 stick, DiPricol, S&B, EFI, Pac Brake, Airlift, AD100, SB OFE, Kore, Thuren, Bilstein; BD; 285/75R18 Toyo AT2's on 2014 factory 18's; 07 Komfort 274TS
My pics

Fisherguy is offline   Reply With Quote Quick reply to this message
Old 10-05-2009, 01:53 PM   #6 (permalink)
Diesel Freak
 
madtrucker66's Avatar
 
Join Date: Dec 2008
Location: Chandler,AZ
Posts: 587
Thanks: 19
Thanked 21 Times in 21 Posts
iTrader Score: 0 reviews
I have read this like 10 times and im still on the fence if I want todo it,But its a great write up.I Just need to find one on cab light haha Great Find.
__________________
For sale
1994 drw 240k,NV4500, super hx40,90hp bully's,3gsk,60springs,banks intake,bhaf,Bigger intercooler,pyro,,boost,custom,box,2,12's,1500w,a the list goes on.
madtrucker66 is offline   Reply With Quote Quick reply to this message
Old 10-13-2009, 01:45 AM   #7 (permalink)
CF Administrator
 
THE STIG's Avatar
 
Join Date: Nov 2008
Location: Utah - S. Texas
Posts: 11,893
Thanks: 1,271
Thanked 4,148 Times in 2,009 Posts
iTrader Score: 6 reviews
Quote:
Originally Posted by madtrucker66 View Post
I have read this like 10 times and im still on the fence if I want todo it,But its a great write up.I Just need to find one on cab light haha Great Find.
it looks intimidating but isnt that bad. just be sure to keep everything clean and take your time
__________________
Powerful - Reliable - Inexpensive. Pick any two at a time, the third is not included.


Some men are born great, some achieve greatness and some get it as a graduation gift. - Robin Williams


THE STIG is offline   Reply With Quote Quick reply to this message
The Following User Says Thank You to THE STIG For This Useful Post:
cudamills (03-31-2011)
Old 10-13-2009, 01:52 AM   #8 (permalink)
Diesel Head
 
ruidosododge's Avatar
 
Join Date: Dec 2007
Location: Franklin, Indiana
Posts: 8,734
Thanks: 2,310
Thanked 850 Times in 698 Posts
iTrader Score: 5 reviews
yup... that is a nice write up... We have swapped about 4 sets now. Just take your time and be clean. It makes it simple. Also having the right tools helps!
__________________
'12 VW Passat Previous Rams: '10,'06,'04,'01
ruidosododge is offline   Reply With Quote Quick reply to this message
Old 10-25-2009, 03:26 PM   #9 (permalink)
Newbie
 
03CummminsBoy's Avatar
 
Join Date: Dec 2008
Location: clermont
Posts: 47
Thanks: 5
Thanked 8 Times in 2 Posts
iTrader Score: 0 reviews
nice write up. no lie. you did a great job on this one. i personally just pulled the injectors out of my 03 thanks to this. i gotta have them sent in to be tested my truck is running like crap. but one thing i did differently which helped me out a ton was instead of using the screw driver or the injector puilling tool. i used a piece of copper wire and a rubber mallet. i wrapped the copper around one end of the bracket on the injector and tied a loop in it. then used the mallet stuck inside the loop to pry out each injector. made pulling them out a breeze.
__________________
2003 2500 Quadcab 5.9 Cummins, 20" ice metal w/ Nitto terra grapplers, air raid intake, BullyDog TripleDog 2.4d Crazy Larry
03CummminsBoy is offline   Reply With Quote Quick reply to this message
Old 11-08-2009, 02:41 AM   #10 (permalink)
CF Administrator
 
THE STIG's Avatar
 
Join Date: Nov 2008
Location: Utah - S. Texas
Posts: 11,893
Thanks: 1,271
Thanked 4,148 Times in 2,009 Posts
iTrader Score: 6 reviews
I ended up making a special prying tool that fits in there beter to pop the injectors up, also noted that 4 out of the 6 connector tubes were a pain to get out, I reused #5 injector line, just screw it back onto the tube and slightly tq it to the right, tube comes right out with no hastle
__________________
Powerful - Reliable - Inexpensive. Pick any two at a time, the third is not included.


Some men are born great, some achieve greatness and some get it as a graduation gift. - Robin Williams


THE STIG is offline   Reply With Quote Quick reply to this message
The Following User Says Thank You to THE STIG For This Useful Post:
cudamills (03-31-2011)
Old 11-08-2009, 03:24 AM   #11 (permalink)
Cummins Nut
 
2003CTD's Avatar
 
Join Date: May 2006
Location: Killeen TX
Posts: 363
Thanks: 27
Thanked 13 Times in 13 Posts
iTrader Score: 0 reviews
Great write up!
__________________
2003 2500, 4X4 Reg. Cab, LB, 48RE, 3:73 gears and a HE351 (Tater Built). AEM Brute Force, UDC (tuned by Coffman Customs), FASS 95, CTS Insight, PML deep transmission pan and 4" Exhaust. Cooper ST/MAXX 295/70/17 on XD Hoss. 2" leveling kit
2003CTD is offline   Reply With Quote Quick reply to this message
Old 11-08-2009, 03:32 AM   #12 (permalink)
GA CUMMINS CREW PREZ & Captain of the USS FAILBOAT!
 
SOUTHERN SMOKE's Avatar
 
Join Date: Dec 2007
Location: ROYSTON, GEORGIA
Posts: 5,250
Thanks: 40
Thanked 297 Times in 199 Posts
iTrader Score: 0 reviews
thanks dude, they will deffinately help some of the do-it-yourself folks on here, myself included...
__________________
2011 3500, stock, 2003 QCSB 4X4 5.9 6spd, Smarty, Valair, K&N, ARP, Topgun, Autometer, 5" Stacks, Smoked Recons, KMC wheels, Cooper 35X12.50's, With enough get up and go to piss off your granny! Blacked Out And Engineered By Southern Smoke, And Dark Side Diesel!

CLICK -------> GEORGIA CUMMINS CREW
SOUTHERN SMOKE is offline   Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Dodge Cummins Diesel Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Display Modes

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


Powered by vBadvanced CMPS v3.2.2

All times are GMT -4. The time now is 03:56 PM.



Powered by vBulletin® Copyright ©2000 - 2014, vBulletin Solutions, Inc.

SEO by vBSEO 3.3.2