Tuesday, May 29, 2012

Dodge Ram: Replacing Fuel Injectors?

How to Remove and replace Fuel injectors on Dodge Ram.

The complete procedure with details and diagrams is provided below.

The procedure here will Cover all U.S. and Canadian models of the Dodge Ram 1500, 2500, 3500, 2WD & 4WD, From Year 2001 - 2005.

  1. Remove or disconnect the following:

    Negative battery cables
    Valve cover
    Fuel line connector
    Connector retainer nut
  2. Use high pressure tool 9015 and remove high pressure connectors. 

    fuel injector
    Fig. Using tool 9015 to remove high pressure connectors-2004

    fuel injector
    Fig. Fuel injector mounting-2004

    Fuel injector removal tool 9010
    Fig. Fuel injector removal tool 9010-2004

  3. Remove the necessary exhaust rocker arms.
  4. Disconnect the injector solenoid wire nuts from top of injectors.
  5. Remove injector hold-down clamp bolts.
  6. Remove the fuel injector using tool 9010 as follows:
    1. Remove rocker housing bolt.
    2. Install lower half of mounting stud to center of rocker housing bridge.
    3. Install upper half of mounting stud to lower half.
    4. Place tool handle to mounting stud and install nut loosely.
    5. Place lower part of clamshells to sides of injector.
    6. Place upper part of clamshells onto tool handle head.
    7. Slide retainer sleeve over pivoting handle.
    8. Depress handle downward to force injector up and out of cylinder head.
  7. Remove and discard the sealing washer from the injector.
To install:
  1. Use a new sealing washer and O-ring on the injector.
  2. Install the injector with the male connector port facing intake manifold.
  3. Fuel injector clamp. Tighten the bolt to 44 INCH lbs. (5 Nm), then loosen the bolts.
  4. Install the high pressure connector and tighten the nut to 11 ft. lbs. (15 Nm).
  5. Alternately tighten the injector hold down bolts to 89 INCH lbs. (10 Nm).
  6. Retighten the high pressure retaining nut to 37 ft. lbs. (50 Nm).
  7. Install solenoid wires and nuts. Tighten nuts to 11 INCH lbs. (1.25 Nm).
  8. Install or connect the following:

    Exhaust rocker arms
    Check valve lash
    Fuel line connector
    Valve cover
    Negative battery cables
  9. Bleed the fuel system.
  10. Start the engine and check for leaks.

These details will help.


Car repair guide?

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