How do I change injectors on a Dodge cummins?

Answer 1

Is the truck a 12 or 24 valve? I have never done a 24 valve but the ingectors are located under the valve cover (Top of engine w/ Cummins logo), and I immagine it would be very simmilar to a 12 valve once you get into them.

12 Valve Injector Install News Summary:

These instructions are written to help you replace injectors in your 12 valve cummins. Most of this was taken from TDR members...

News Content:

Remove Dodge Cummins....etc. plate from valve cover

Use an air gun to blow all loose material from the top of the cylinder head.

Remove the high pressure fuel line clamps (8mm wrench)

Remove the #1 valve cover. Note: this provides room to get the fuel lines out of the way while removing the injector body nut. The first three cylinder fuel lines pass between 1 and 2 valve covers.

Remove the large retainer nuts from the injectors ( 17mm wrench or deep well socket, some have used a 15/16" deepwell socket)

Remove enough fuel drain bolts and move the manifold out of the way (10 mm wrench).

Position fuel lines out of the way for each injector as you go (dont be afraid to bend them a little, but not too much!)

to get each injector out use a set of pliers (vise grips are a handy item) to grab the injector, turn and wiggle it out. Some can be difficult. I had to use some force for this step. The injector will turn some. They have a ball like a ratchet uses to hold a socket. (as you will probably notice on the new injectors)

If the injectors are hard to remove, put a nut on top of the injector where the fuel line came off and pry up; they come out easily.

if this doesn't work you can use the Cummins injector puller and all six will take about 5 minutes.

There is a "seal" where the copper washer seats and make sure there is no crud on it so the seal will be good. You have to use a light and crawl up to see down NO.'s 5 & 6.

When replacing the injector lightly oil the body insert it in the hole and rotate the injector until the notch on the side of the injector finds the depression in the head, when it is in position, the injector will not rotate any more. note:(wouldn't hurt to leave one old one installed for comparison until several new ones are down the whole way)

Put some never seeze on the injector body nut and torque the retainer nut to 44 ft-lbs.

Reinstall the lines on the pump fully (if you disconnect them)

Finger tighten the high pressure fuel line nuts on the injectors.

When you reinstall the injector drain manifold get all the little screws to start significantly before the final tightening. They crossthread easily.

Reinstall all the high pressure fuel line clamps

Reinstall the fuel drain manifold

Crank the engine until there is fuel coming out of all injector lines, then tighten the high pressure fuel nut and start the engine. It may miss and run rough for a few moments, then begin running smoothly.