While the Cummins turbo diesel found in Dodge trucks is highly reliable an occasional concern is long engine crank over and no starting. Many times this is caused by bad fuel injectors. In this video we show you briefly what’s involved in changing fuel injectors in a 2004 Dodge diesel truck.
• The first procedure involves removing electrical connectors to the rocker arm cover, the intake tube and air heaters must be removed and then the valve cover. We can now see the rocker arms and top of the fuel injectors with their wiring connectors.
• Next step is to remove the fuel lines from the transfer tubes, often a time consuming task as the transfer tubes turn with the line fitting and the transfer tube nuts must first be tightened before the line nuts can be loosened.
• After the lines are removed, the transfer tubes are unbolted and pulled out.
On the bench you can see the 6 old injectors laid out.
Here are the new injectors along with cleaned transfer tubes ready for installation.
These transfer tubes are of a rather unique design and require some very special installation procedures to ensure proper sealing and avoid damage.
• Here we install the injector into the cylinder head, then install the bolts and torque down the injector.
• Transfer tubes are then installed, the injector nuts are then backed off and transfer tubes are torqued to spec.
• Injectors are then re-torqued to proper spec and all previously removed components are reinstalled.
After reassembly it’s time to start the engine. That’s how it should sound: the start time is almost instantaneous.