RAM 2500 Truck 2WD L6-5.9L DSL Turbo VIN 7 (2001)
Fig. 17 Installing Injector To Adaptor Tool 8301
4. After injector has been removed, obtain bench-mount fuel injector tester OTC (SPX) part number 4210 (Fig. 16) (or equivalent). Install Special
Tool number 8301 (Fuel Injector Adapter) to 4210 tester. Install fuel injector into 8301 adapter. Be sure tip of adapter tool 8301 is aligned to inlet
hole at side of injector (Fig. 17) before tightening tool. Tighten tool 8301 to injector. Position container below injector before testing.
5. Refer to operating instructions supplied with pressure tester for procedures.
a. Check opening pressure or "pop" pressure. Pressure should be approximately 31,026 kPa (310 bars) or (4500 psi ± 250 psi). If fuel injector
needle valve is opening (popping) too early or too late, replace injector.
b. Perform a leak-down test on injector. Apply pressure with injector tester. The injector should not leak (drip) fuel with pressure at
approximately 20 bars (291 psi) lower than pop pressure.
c. Operate tester lever quickly several times to check injector spray pattern. Verify fuel is spraying from each injector nozzle hole. Injector
should also spray evenly from each nozzle hole.
d. Pay attention to size and shape of spray plumes. They should all be equal. If possible, compare spray pattern to that of a new fuel injector with
same part number. Checking each plume for consistency is an excellent indicator of injector performance. Even if only one nozzle hole is
plugged, significant performance problems could result.
e. Look for burrs on injector inlet.
f.
Check nozzle holes for hole erosion or plugging.
g. Inspect end of nozzle for burrs or rough machine marks.
h. Look for cracks at nozzle end.
i.
Check nozzle color for signs of overheating. Overheating will cause nozzle to turn a dark yellow/tan or blue (depending on overheating
temperature).
j.
Look at end of injector tube where it meets injector. A small, shiny band should be seen at this point. The band should have a consistent
thickness. If not, injector could be leaking into fuel return.
k. If any of these conditions occur, replace injector.