Dodge Ram Truck 1500-2500-3500. Manual — part 1488

3. Remove valve cover. Refer to Engines for procedures.

4. Remove all 12 fuel injector wire harness nuts (1)

securing integrated wiring harness to all 6 fuel
injectors.

5. An integrated fuel injector wire harness / valve

cover gasket (2) is used. After all 12 nuts (1) have
been removed, remove this integrated gasket.
Before removing gasket, disconnect engine wiring
harness at both electrical connectors (3).

6. Remove necessary high pressure fuel line connecting necessary fuel injector rail to high pressure connector.

Refer to Fuel Line Removal for procedures.

7. A connector retainer (nut) is used on each connector tube. Remove this nut(s) by unthreading from cylinder

head.

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8. Using special high-pressure connector removal tool

#9015 (2) remove necessary high-pressure con-
nector(s) from cylinder head. Tool #9015 threads
onto connector tube. Use tool to pry connector
tube(s) from cylinder head.

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9. Remove 2 fuel injector hold-down clamp bolts (1)

at each injector being removed.

10. Remove

necessary

exhaust

rocker

arm

assembly(s).

11. USING TOOL #9010:

a. Special Tool #9010 is equipped with 2 clam-

shell clamps, a sliding retainer sleeve to retain
the clamshell clamps, a 2–piece mounting
stud, and a pivoting handle. Do not attempt to
remove the fuel injector with any other
device. Damage to injector will occur.

b. The rocker housing is bolted to the top of cyl-

inder head. The mounting stud from tool #9010
was meant to temporarily replace a rocker
housing mounting bolt. Remove the necessary
rocker housing mounting bolt. These mounting
bolts are located at the center of each of the 3
rocker housing support bridges.

c. Install and tighten 2–piece mounting stud to rocker housing. If removing the #6 fuel injector, separate the

2–piece mounting stud. Install lower half of mounting stud to center of rocker housing bridge. Install upper
half of mounting stud to lower half.

d. Position tool handle to mounting stud and install handle nut. Leave handle nut loose to allow a pivoting

action.

e. Position lower part of clamshell halves to sides of fuel injector (wider shoulder to bottom). The upper part of

clamshell halves should also be positioned into machined shoulder on the handles pivoting head.

f. Slide the retainer sleeve over pivoting handle head to lock clamshell halves together.

g. Be sure handle pivot nut is loose.

h. Depress handle downward to remove fuel injector straight up from cylinder head bore.

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12. Remove and discard injector sealing washer (2).

This washer should be located on tip of injector,
or may have remained in the injector bore..

INSTALLATION

1. Inspect fuel injector:

a. Look for burrs on injector inlet.

b. Check nozzle holes for hole erosion or plug-

ging.

c. Inspect end of nozzle for burrs or rough

machine marks.

d. Look for cracks at nozzle end.

e. If any of these conditions occur, replace injec-

tor.

2. Thoroughly clean fuel injector cylinder head bore.

Blow out bore hole with compressed air.

3. The bottom of fuel injector is sealed to cylinder

head bore with a copper sealing washer (shim) (1)
of a certain thickness. A new shim (1) with correct
thickness must always be re-installed after remov-
ing injector. Measure thickness of injector shim (1).
Shim Thickness: 1.5 mm (.060”)

4. Install new shim (1) (washer) to bottom of injector.

Apply light coating of clean engine oil to washer.
This will keep washer in place during installation.

5. Install new o-ring to fuel injector. Apply small

amount of clean engine oil to o-ring.

6. Install injector into cylinder head with male (high-

pressure) connector port facing the intake manifold.
Push down on fuel injector mounting flange to
engage o-ring and seat injector.

7. Tightening Sequence:

a. Install fuel injector holdown clamp (mounting

flange) bolts. Do a preliminary tightening of
these bolts to 5 N·m (44 in. lbs.) torque.
This preliminary tightening insures the fuel
injector is seated and centered.

b. After tightening, relieve bolt torque, but leave both bolts threaded in place.

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