All right, we're doing a common rail injector install for an '06 Dodge today. Customers
complain of high EGTs. A truck had over a 100,000 miles on it, so we've probably got
some ball seat erosion issues, so we're going to put brand new Robert Bosch injectors in.
We're going to go through the steps to take out and re-install common rail injectors.
We're going to start with first step in the entire process, which is removing the fuel
rail. Here at Thoroughbred we remove the fuel rail in one complete pack, we don't remove
any lines or anything from the fuel rail itself, we'll actually take it all out in one pack.
This is the head size of the injectors, at the actual head in the injector. You just
loosen these up, remove them from the injectors, you've got hold down clamps here all the way
down the rail holding it to the intake manifold.
Then there's three bolts here, here, and here that hold the rail itself to the head. Remove
the fuel feed line coming from the CP3, it's on the bottom side of this, the overflow valve,
undo your electrical connectors and this will come out in one shot off the head.
Then once we're at the head, we need to remove the feed tubes. At each feed tube on the common
rail head there's a retaining nut that holds the feed tube in, that's this here. And then
you have the feed tube itself, which is here, and we'll show you how to remove it. To remove
the feed tubes we use a Snap-On J149, and you can get from any Snap-On dealer. Just
screw that onto the feed tube like so, off just a little bit, and then just simply use
a pry bar or a screwdriver and pry like that. There we go voila. The feed tubes come right
out.
The feed tubes have got two ball bearings on them. There's a channel cut in the head
so I won't re-installation, what we do is we'll just line that up by turning the feed
tube side to side, now let's find our groove, and then push feed tube back inside the head.
All right.
Next we're going to go for the valve cover. Once we have the valve cover off, we'll show
you guys where we're at. The next step in common rail injector removal is taking off
the valve cover gasket. The [inaudible 00:02:31] Cummins valve cover gasket is an integrated
circuit, it's got all the wires running through it, going to each individual injector, two
nuts on top of the injector, we'll do that for all six injectors, and then we're going
to remove the valve cover gasket and go for the exhaust rocker arms, which is the longer
of the two rocker arms. We'll remove those and that'll give us access to our injectors.
All right, we've got our exhaust rocker arms off now. We're ready to remove the injectors.
To remove the injectors, we take the valve bridge off each exhaust valve. Then you have
two bolts, here and here, metric eights and we're going to remove those, and then from
this side of the injector we'll get a pries tool underneath of here, right at the injector
hold down here, and use that to pries the injector out of the bore. Do that for all
six cylinders.
These are our brand new Robert Bosch 505 injectors. We call them a 505 the Bosch number is 0986435505
for the 04 and a half to 0759s with the 325 horsepower motor in it. Before we install
these, we'll put a little bit of petroleum jelly around this O-ring right here, and then
we'll go ahead and place them in the head.
All right, putting the injectors in the head, one of the biggest things that you want to
do is make sure that you've got the feed hole of the injector pointed towards where the
feed tube is going into the head, which will be the driver's side. We'll take the injector,
we've got our petroleum jelly on it, ready to go in the bore, make sure nothing's in
the bore of the feed hole, and we'll orient it towards that feed tube on the head. Okay,
we'll get her seated like this, top of the head the electronics, take a rag, double it
over so you've got a good soft cushion and just simply push, it'll click like that, just
that easily, and the injector is in. One of the easiest ways to know whether you've got
the injector seated, and seated right as you can go back and put your feed tubes back in
the head, and you can wiggle the injector and if the feet tube is in there right when
you wiggle it, you won't have very much play at all, just a little bit, and you'll also
see the feed tubes wiggle.
We're going to put our other six injectors in, and then we're going to put the feed tubes
in, and show you what we're talking about there.
All right, we've got our injectors back in, haven't put our bolts in yet because we want
to show you how we do on the feed tubes here. With the feed tubes again, you want to have
the ball bearings up and they'll go in the groove here in the head, and when you start
them in the head you can kind of like turn them left to right just like this right here,
and that lets you show that you got the bearing in the groove. That's right there. Just take
a blunt end of any tool here, we go back with the same tool that we actually remove it just
to protect the threads on it. Feed it on a couple, two or three turns and pop the feed
tube back in. Remove the installation tool or the removable tool. Okay.
Now, here's the true test to see whether you've gotten the injectors and the feed tubes lined
up here. All right, we're going to take the head of the injector and move it, and we should
see movement out of this feed tube right here. All right, work the injector back and forth,
feed tubes moving, so we've got positive engagement of the feed tube into the injector. We'll
put our nuts back on here and tighten everything back down, valve bridges, the exhaust valves,
run the overhead back on the motor, check for valve clearance, and we're right there
where we want to be. We'll be putting the valve cover back on, and putting all the electronics
back on. Make sure you run your torques on everything here, injector hold down bolts,
the rocker arm bolts. Make sure you go back through your overhead on the motor. Check
your intake in your exhaust valve clearances, and that's going to be it. Installation is
reverse of removal.