streetsmoker

Need to change out my #5 injector and have to swap the current DDP tip onto the new injector. How hard is this to do, and are there any special tools needed??? Allready know procedure of pulling and replacing injectors, just need info on the nozzle change. Pics or graphics would be great. Thanks.

dieselfan

not hard if you have a vice and muscle. i used a boat trailer as my vice. the injector fit perfectly in one of the c-channel grooves. if that makes sense.

gus's 03

grind a wrench thinner so it'll fit in the grove of the body.
15mm deep socket to remove nut, remove tip. clean every thing off with brake cleaner, you want the nozel to body surface clean and dry. if there is moisture itll get traped and even .0005" is still space for fuel to eventualy go. tighten nut to 55ft/lb. done....

04DEEZELRAM

Ya and i think it a 22mm wrench you have to grind down to hold the injector

skynyrd

swapping out the injector isn't that bad.
- - Common Rail injector Removal and install instructions - -
Tools Needed:
T15 Torx
13mm Wrench
22mm wrench
15mm wrench
19mm Wrench
10mm socket
8mm socket
11mm socket
15mm socket
24mm socket
Torque Wrench
Assorted extensions and ratchets
Caution: This system is pressurized, and will cause severe injury. Under no circumstances should the high pressure fuel lines be loosened to bleed. The system is self bleeding. You can be maimed or killed.
1: Disconnect Negative Battery cables.
2: Remove 10mm bolts that hold intake, dipstick, and wiring.
3: Remove 11mm Intercooler boot clamp.
4: Remove 10mm bolts on plastic valve cover, cover.
5: Remove 10mm bolts holding upper valve cover.
6: Remove all wiring from valve cover, including 8mm injector wires.
7: Remove 10mm bolts holding riser box.
8: 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.
9: Remove exhaust rocker cross overs. Keep these in order as well.
10: Disconnect fuel rail supply line.
11: Disconnect fuel return line from pressure limiting valve, and bend gently out of the way.
12: Disconnect 19mm high pressure lines from injector connector tubes.
13: Loosen 13mm bolts on back of head that hold bracket just behind last injector line.
14: Remove 13mm bolt from rear fuel line holder. (04.5 and up only)
15: Remove 10mm fuel line hold down.
16: Remove 10mm bolts holding fuel rail.
17: Remove fuel rail assembly.
18: Remove map sensor from intake with T15 torx.
19: Remove 15mm rear engine lift bracket bolts and bracket.
20: Remove 24mm nuts holding high pressure connector tubes.
21: Remove connector tubes.
22: Remove 8mm injector hold down bolts.
23: Carefully pry injectors out of injector bore.
24: Grind 22mm wrench thin enough to fit between the two loose collars on injector.
25: Clamp wrench into vise, and remove the collar holding injector nozzle to body.
26: Inspect nozzle for cracks.
27: Taking care to clean all parts, replace new Extrude Honed nozzles, and torque to 55 ft lbs.
28: Replace copper nozzle washers, with new washers.
29: Reinstall injectors into injector bores, and make sure they click into place, also make sure the injector supply hole is oriented towards the connector tube.
30: Insert connector tubes into place, ***** up. Make sure they click into place.
31: Replace connector tube nuts, and finger tighten.
32: Replace injector hold down bolts, and finger tighten to equal lengths on either side of each injector.
33: Torque connector tube nuts to 37ft lbs.
34: Torque injector hold down nuts to 89in lbs.
35: Reinstall engine lift bracket, torque to 57ft lbs.
36: Install fuel Rail assembly.
37: Connect high pressure injector supply lines, and finger tighten.
38: Connect high pressure supply line, and finger tighten.
39: Install fuel rail bolts, and injector supply line hold downs, and torque to 18ft lbs.
40: Torque high pressure injector supply lines to 22ft lbs.
41: Install fuel line hold down bracket at rear of fuel rail, and torque to 18 ft lbs.
42: Tighten high pressure supply line to 22ft lbs.
43: Reconnect fuel return line with washers, and torque to 22ft lbs.
43: Reinstall map sensor.
44: Install exhaust valve cross overs, in same order they were removed.
45: Install exhaust valve rockers in the same order, and tighten to 27ft lbs. make sure the pushrod is properly seated into the lifter.
46: Install riser box, and torque to 18ft lbs.
47: Install wiring onto injectors, and plug main harnesses in. Do not over tighten the nuts on top of injectors.
48: Reinstall safety bracket behind #6 injector. This is a bracket designed to keep the occupants safe from fuel in a crash. Do not discard.
49: Install upper valve cover, and torque to 18ft lbs.
50: Reinstall intake, and tighten to 18ft lbs.
51: Retighten intercooler boot.
52: Reinstall dip stick, and wiring onto intake.
53: Reinstall valve cover, cover.
54: 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.

jwb600

you wont be able to do it without grinding down the wrech like is stated above. its way easier to just go buy one and grind it down like they say.
they are really good instrucions on the dynomite website that I recall on how to change out the nozzles.

Goober

SKYNYRD is there any pics to go with the write up.