how to install injectors
 

can someone give or tell me where some good directions for installing injectors. i ve been searching only found a little, both had different steps.one had what to torque fuel lines to, other didnt say anything about that. just want to do it right. thanks, dieselfan

cummins told me to take the valve cover off and you will see a pulg unplug it there will be two bolts to each injector but you will only see the top one remove it flip the braket over and pull the injector out lut new one in and retork the bolt plug it back in

This might help... found it using the search feature:

injector install thread

No plug on anything from 89-2002. He has a 2001.

thanks i found that one yesterday, i figured they had others. i was trying to get away without taking off the intake manifold. is it a must? thanks dieselfan

Go to thedieselgarage.com and there is a step by step set of instructions with pictures. Look on the right side of the page. The link to it is there.

I used the Diesel Dynamics instructions and they were very good. I would reccomend getting an intake horn gasket, because I ripped mine even though I was being careful. It's only about $2.50 at the Dodge dealer.

Brad

It can be done without taking off the air horn, but it requires a "modified" wrench.

Best bet is to remove the air horn. Get 2 gaskets and I keep no less than a dozen on hand. I tend to swap sticks a little.

What specific questions do you have? It's pretty straight forward.

Remove the air horn by unbolting and rotating out of the way.

Loosen all the injector nuts, they must be free of the head.

Remove the valve cover. Pull all the bolts out first, it's and easier fight. Then move the valve cover over to the left side and over the coolant line, it'll come straight out.

Remove the injector retainer bolts. Only remove the bolt towards the front. The rear of the retainer is slotted.

With one of the short air horn bolts, screw it into the top of the injector. Do not pull it out yet!!

With a small flat blade screwdriver, gently pry the cross tube out of the head a small amount. You are just trying to pull it back enough to allow the injector to come out.

Now, using a pair of pliers, pry up on the bolt using a rocker arm. It should pop right out. Make sure the crosstube is pulled back far enough before prying or you will damage the cross tube.

Check all the injectors to be sure the copper washer comes out with them.

Reinstall new injectors. Using the air horn bolt as a handle, set the injector back into the hole AFTER the cross tube is pulled back. Hand pressure should get the injector seated, but a small rubber mallet can be used.

Install the injector retainers and bolts. DO NOT TIGHTEN BOLTS.

Thread all the injector line nuts back into the head. Snug with a wrench. NO TORQUE JUST SNUG.

Torque the injector retainer bolts to 89 in lbs.

Torque injector line nuts 2, 5 and 6 to 28 ft lbs.

Tighten all injector line retaining clamps.

Loosen lines #1, 3 and 4 This is to allow bleeding.

Install valve cover.

Install air horn.

Bump key and allow lift pump to cycle. Repeat this process several times.

Hold accerator at half throttle. Crank engine for no more than 5 seconds. If the truck starts or attemts to start, immediately shut off the key.

Look at the loose injector lines. Wherever you see fuel, torque to 28 ft lbs.

repeat cranking process until you have fuel at least 2 injector lines. Torque remaining lines to 28 ft lbs.

Get in truck, hold throttle at half way, crank and allow to start. Use a small amount of throttle until engine smooths out, allow to idle. Check under hood for any fuel leaks. Tighten lines as necessary.

Dave

thanks i got them in yesterday, not near as bad as i thought. i bought a crowfoot wrench for the #6 injector line and didnt even use it. i had a guy help me, thats changed his like 10 times, so i felt better about doing them with him watching. i will do my valve lash today since i didnt have time yesterday and engine was hot[dummy] . thanks again, dieselfan