Repair 7

How to Remove the Injectors on a 2004 Dodge Diesel

Diesel engines are more commonly found on larger trucks. The standard engine in a 2004 Dodge Ram 2500 is a six-cylinder, 5.9-liter, turbocharged diesel engine. This engine uses a high-pressure fuel injected system to deliver fuel to the engine. The fuel injectors on the 2004 Dodge diesel engine are located on top of the engine. Removal requires a special tool. You will also need to remove the fuel in the fuel lines before replacing the injectors.

Instructions

1

Loosen the bleed bolt on the fuel rail with a socket wrench. Push the fuel primer on the fuel transfer pump until the fuel coming from the bleed valve no longer has air bubbles. Tighten the bleed bolt to 72 inch-pounds with a torque wrench.

2

Disconnect the negative battery cable by loosening the terminal nut with a socket wrench. This will prevent the accidental discharge of fuel as you remove the fuel injectors. Disconnect the valve cover with a socket wrench and detach the fuel lines from the fuel injectors.

3

Remove the retaining nut for the high-pressure fuel connector on each fuel injector. Disconnect the high-pressure connectors from the fuel injectors with tool 9015.

4

Disconnect the exhaust rocker arms with a socket wrench. Remove the retaining nuts from the solenoid wire, located on top of the fuel injectors. Disconnect the hold-down clamp bolts on the fuel injector. Remove the rocker-housing bolt with a socket wrench.

5

Connect the lower half of the mounting stud on tool 9010-2004 to the center of the bridge for the rocker housing. Connect the upper half of the mounting stud on tool 9010-2004 to the lower half of the mounting stud.

6

Connect the handle of tool 9010-2004 to the mounting stud on the tool. Tighten the nut on the tool to loosely connect the handle to the mounting stud. Connect the lower half of the clam shells on the special tool to the sides of the fuel injector. Connect the upper half of the clam shells to the head of the tool handle.

7

Slide the retaining sleeve over the pivoting handle of tool 9010-2004. Push the handle of the tool down to force the fuel injectors out of the cylinder heads. Remove the fuel injectors from the cylinder heads.