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Fuel Injector: Installation

WARNING: This page is about a different car, the 2004 Dodge Pickup and 2004 Dodge Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Two different fuel injectors are used (early and late). Although they physically look the same, they are NOT interchangeable. Be sure to reference the injector part number when replacing a fuel injector. This part number is laser-burned onto the injector. Failure to replace with the proper injector will cause severe engine damage.
  1. Inspect fuel injector: 
    1. Look for burrs on injector inlet.
    2. Check nozzle holes for hole erosion or plugging.
    3. Inspect end of nozzle for burrs or rough machine marks.
    4. Look for cracks at nozzle end.
    5. If any of these conditions occur, replace injector.
  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) of a certain thickness (Figure). A new shim with correct thickness must always be re-installed after removing injector. Measure thickness of injector shim (Figure). Shim Thickness: 1.5 mm (.060") 
  4. Install new shim (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:
    1. 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. 
    2. After tightening, relieve bolt torque, but leave both bolts threaded in place.
    3. Install high-pressure connector and retaining nut. Do a preliminary tightening to 15 N.m (11 ft. lbs.) torque.
    4. Alternately tighten injector holdown bolts to 10 N.m (89 in. lbs.) torque.
    5. Do a final tightening of the high-pressure connector and retaining nut. Tighten to 50 N.m (37 ft. lbs.) torque.
  8. Connect injector solenoid wires and nuts to top of injectors (Figure). Tighten connector nuts to 1.25 N.m (11 in. lbs.) torque. Be very careful not to overtighten these nuts as damage to fuel injector will occur. 
  9. Install exhaust rocker arm assembly. Refer to OVERHAUL - 5.9L DIESEL .
  10. Set exhaust valve lash. Refer to OVERHAUL - 5.9L DIESEL .
  11. Install high pressure fuel line. Refer to SPECIFICATIONS . Be sure to use a secondary back-up wrench on the connector nut (fitting) while torquing fuel line fitting.  Refer to FUEL LINES for additional information.
  12. Install valve cover. Refer to OVERHAUL - 5.9L DIESEL .
  13. Install breather assembly.
  14. Connect negative battery cables to both batteries.
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