Dodge@KY1997

How hard is it to replace the injector O-rings on my 96 CTD? Is it just a matter of taking off the bar that runs across them and pulling them out?

marine4life

why do you want to replace the orings? Is it leaking, if it is then the oring are not your problem it is your crush washers on the injector tips. The oring is on there to keep dirt and other stuff going down into the cylinder. The crush washer is what keeps the cylinder sealed off. To get the injector out you will need 4 tools, a 10mm,15mm,19mm, and a 24mm. Take off the return fuel line(the bar you spoke of) with the 10mm. Be careful not to drop the banjo bolts or the copper washers that are on both sides of the return line. Then take off the fuel line of the injector with the 19mm. You can try to move it out of the way just enough to fit your 24mm down there to get at the nut that holds the injector down. These fuel lines can take a good bend before breaking or cracking so don't worry about it too much. Once you get the nut loosened up pull it out. Next put the 15mm wrench on the injector at the base where it is squared off. Once it is snug in there wrench it back and forth until it breaks loose. You should have a quarter to half inch of play back and forth. You now should be able to pull the injector out by hand. At the bottom of the nozzle you will see the copper crush washer now pull this one off and put a new one on. Now install everything in the reverse order, make sure you atleast put an oring that fits snug over the injector back on before you put the hold down nut(the stock ones are the square kind but those aren't too easy to find at your hardware store). Now tighten the hold down nut extremely tight because if you don't then you will be doing this all over again to tighten up more. When putting on the fuel return line make sure you start at the back and make your way forward(do not forget the doube sided copper washer. After hooking everything back up and start the truck. It might run rough for a little while before it works the air out of the system. Look underneath the hood and check the injector hold down nut at the bottom. Do you see fuel or air bubbles coming up? If you don't then you are good to go. PM with any more questions.