RAM 4500 Chassis Cab Truck 2WD L6-6.7L DSL Turbo (2008)
Fuel Injector: Service and Repair
Fuel Injector - Installation
INSTALLATION
1. Inspect fuel injector :
a. Look for burrs on injector inlet.
b. Check nozzle holes for hole erosion or plugging.
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 injector.
2. Record six-digit alphanumeric correction code located on the side of injector.
3. Inspect high-pressure fuel injector connector for :
a. Damaged tip.
b. Loose of missing alignment pin.
c. Cut or missing O-ring.
4. Thoroughly clean fuel injector cylinder head bore. Blow out bore hole with compressed air.
5. 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 removing injector. Measure thickness of injector shim (1). Shim Thickness: 1.5 mm (.060")
6. 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.
7. Install new O-ring to fuel injector. Apply small amount of clean engine oil to O-ring and injector bore.
8. 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.
9. Tightening Sequence:
a. Install fuel injector holdown clamp (mounting flange) bolts. Be sure the clamp is perpendicular to the injector body. Do a preliminary
tightening of these bolts to 5 Nm (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.
c. Install high-pressure connector (13) and retaining nut (12). Do a preliminary tightening of nut (12) to 15 Nm (11 ft. lbs.) torque.
