12/1/2020 Fuel System • Fuel Injection, Diesel • Injector(S), Fuel • Removal • 2006 Dodge RAM 1500, 2500 Pickup (5.9L) - DH • MotoLogic
Fuel System • Fuel Injection, Diesel • Injector(S), Fuel • Removal
REMOVAL
Labor Operations: Click to display a list of Labor Operations associated with this procedure Special Tools: Click to display a list of tools used in this procedure
NOTE: Six individual, solenoid actuated high-pressure fuel injectors are used. The injectors are vertically mounted into a bored hole in the top of the cylinder head. This bored hole is located between the intake/exhaust valves. High-pressure connectors, mounted into the side of the cylinder head, connect each fuel injector to each high-pressure fuel line.
NOTE: Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a scan tool.
In addition, if a new ECM is installed, use a scan tool to program all six of the injector codes from the original fuel injectors into the new ECM.
NOTE: If the fuel injectors are being removed such as for engine teardown or diagnostic purposes, be sure to mark each injector with its corresponding cylinder number. The fuel injectors MUST be reinstalled into the original (same) cylinder due to the fuel injector correction code.
1. Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables.
2. Removethe engine cover.
3. Remove breather assembly and tubes.
4. Remove valve cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
NOTE: Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector and is used to identify injector calibration.
5. Mark each injector (2) with its corresponding cylinder number. If required, make note of each fuel injector six-digit alphanumeric correction code (1).
12/1/2020 Fuel System • Fuel Injection, Diesel • Injector(S), Fuel • Removal • 2006 Dodge RAM 1500, 2500 Pickup (5.9L) - DH • MotoLogic
6. Remove all 12 fuel injector wire harness nuts (1) that secure the integrated wiring harness (4) to all 6 fuel injectors (2).
7. An integrated fuel injector wire harness / valve cover gasket (2) is used. Before removing gasket, disconnect engine wiring harness at both electrical connectors (3). After all 12 nuts (1) have been removed, remove this integrated gasket.
8. Remove necessary high pressure fuel line connecting the necessary fuel injector rail to high pressure connector.
Refer to Fuel Line Removal for procedures .
10. Thread High Pressure Connector Remover 9015 (4) onto high-pressure connector tube (1) located in cylinder head.
11. Using Thread High Pressure Connector Remover 9015 (2), pry the high-pressure connector tube(s) (4) from the mounting hole(s) (1) as necessary, located on the left side of the cylinder head (3).
12/1/2020 Fuel System • Fuel Injection, Diesel • Injector(S), Fuel • Removal • 2006 Dodge RAM 1500, 2500 Pickup (5.9L) - DH • MotoLogic
12. Remove 2 fuel injector hold-down clamp bolts (1) at each injector (2) being removed.
13. Remove necessary exhaust rocker arm assembly(s).
NOTE: The rocker housing is bolted to the top of cylinder head. The mounting stud from Fuel Injector Removal/Installer 9010A was meant to temporarily replace a rocker housing mounting bolt.
14. Remove the necessary rocker housing mounting bolt. These mounting bolts are located at the center of each of the 5 rocker housing support bridges.
CAUTION: Fuel Injector Removal/Installer 9010A is equipped with 2 clamshell clamps, a sliding retainer sleeve
18. Slide the retainer sleeve over pivoting handle head to lock clamshell halves together. Be sure handle pivot nut is loose.
19. Depress handle of Fuel Injector Removal/Installer 9010A downward to remove fuel injector straight up from cylinder head bore.
NOTE: If the fuel injectors are being removed such as for engine teardown or diagnostic purposes, be sure to mark each injector with its corresponding cylinder number. The fuel injectors MUST be reinstalled into the original (same) cylinder due to the fuel injector correction code.
20. Remove and discard injector sealing washer (2). This washer should be located on tip of injector (1), or may have remained in the injector bore.
NOTE: Do not install new fuel injectors unless the alphanumeric codes have been recorded.
21. Measure injector sealing washer (1).
