Ram Truck 1500, 2500 & 3500 (2006-2008)

Injectors

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Fuel Injector Correction Code Programming



  1. Turn ignition switch ON .
  2.  
  3. Using a diagnostic scan tool, select ECU view, PCM, Miscellaneous functions.
  4.  
  5. Select injector quantity adjustments and click start.
  6.  
  7. Choose appropriate cylinder number and click next.
  8.  
  9. Click on show keyboard.
    NOTE
    A fault code will be set if incorrect serialization codes have been inputted.

  10.  
  11. Input six-digit Injector Correction Code and click enter.
  12.  
  13. Review code as it was typed, then click Next if correct, or edit if necessary.
  14.  
  15. Repeat the preceding steps for other cylinders if necessary.
  16.  
  17. Once all fuel injector correction codes are entered, cycle the ignition to complete.
  18.  

Removal & Installation



5.9L & 6.7L Engine

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 diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM.

Click image to see an enlarged view

Fig. Injector correction code location


NOTE
The valve cover and valve cover gasket will need to be removed in order to manually record the values from the original injectors. Contact cleaner or brake cleaner may be used to clean the fuel injector.


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. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables.
  4.  
  5. Remove vanity cover.
  6.  
  7. Remove breather assembly and tubes.
  8.  
  9. Remove valve cover.
  10.  
  11. Remove all 12 fuel injector wire harness nuts securing integrated wiring harness to all 6 fuel injectors.
  12.  
  13. An integrated fuel injector wire harness / valve cover gasket is used. After all 12 nuts have been removed, remove this integrated gasket. Before removing gasket, disconnect engine wiring harness at both electrical connectors.

    Click image to see an enlarged view

    Fig. Integrated fuel injector wire harness / valve cover gasket

  14.  
  15. Remove necessary high pressure fuel line connecting the necessary fuel injector rail to high pressure connector. Refer to Fuel Line Removal for procedures.
  16.  
  17. A connector retainer (nut) is used on each connector tube. Remove this nut(s) by unthreading from cylinder head. These nuts hold the fuel injector retainers to the fuel injector.
  18.  
  19. Using special high-pressure connector removal tool No. 9015 (4) remove necessary high-pressure connector(s) from cylinder head. Tool No. 9015 threads onto connector tube. Use tool to pry connector tube(s) from cylinder head.

    Click image to see an enlarged view

    Fig. Special high pressure connector removal tool No. 9015

  20.  
  21. Remove 2 fuel injector hold-down clamp bolts at each injector being removed.
  22.  
  23. Remove necessary exhaust rocker arm assembly(s).
  24.  
  25. Remove fuel injector(s) with Special Tool 9010 as follows:
    1. Special tool 9010 is equipped with 2 clamshell clamps, a sliding retainer sleeve to retain the clamshell clamps, a 2-piece mounting stud, and a pivoting handle. Do not attempt to remove the fuel injector with any other device. Damage to injector will occur.
    2.  
    3. The rocker housing is bolted to the top of cylinder head. The mounting stud from tool No. 9010 was meant to temporarily replace a rocker housing mounting bolt. Remove the necessary rocker housing mounting bolt. These mounting bolts are located at the center of each of the 5 rocker housing support bridges.
    4.  
    5. Install and tighten 2-piece mounting stud to rocker housing. If removing the No. 6 fuel injector, separate the 2-piece mounting stud. Install lower half of mounting stud to center of rocker housing bridge. Install upper half of mounting stud to lower half.
    6.  
    7. Position tool handle to mounting stud and install handle nut. Leave handle nut loose to allow a pivoting action.
    8.  
    9. Position lower part of clamshell halves to sides of fuel injector (wider shoulder to bottom). The upper part of clamshell halves should also be positioned into machined shoulder on the handles pivoting head.
    10.  
    11. Slide the retainer sleeve over pivoting handle head to lock clamshell halves together.
    12.  
    13. Be sure handle pivot nut is loose.
    14.  
    15. Depress handle downward to remove fuel injector straight up from cylinder head bore.

      Click image to see an enlarged view

      Fig. Special tool 9010

    16.  

  26.  
  27. Remove and discard injector sealing washer. This washer should be located on tip of injector, or may have remained in the injector bore.

    Click image to see an enlarged view

    Fig. Injector tip (1), sealing washer (2)

  28.  
  29. Measure sealing gasket (washer).
    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.


    NOTE
    Do not install new fuel injectors unless the alphanumeric codes have been recorded.



    Click image to see an enlarged view

    Fig. Measuring sealing washer

  30.  

To install:

  1. Inspect fuel injector(s) as follows:
    1. Look for burrs on injector inlet.
    2.  
    3. Check nozzle holes for hole erosion or plugging.
    4.  
    5. Inspect end of nozzle for burrs or rough machine marks.
    6.  
    7. Look for cracks at nozzle end.
    8.  
    9. If any of these conditions occur, replace injector.
    10.  

  2.  
  3. Record six-digit alphanumeric correction code located on the side of injector.
  4.  
  5. Inspect high-pressure fuel injector connector(s) as follows:
    1. Damaged tip.
    2.  
    3. Loose of missing alignment pin.
    4.  
    5. Cut or missing O-ring.
    6.  

  6.  
  7. Thoroughly clean fuel injector cylinder head bore. Blow out bore hole with compressed air.
  8.  
  9. The bottom of fuel injector is sealed to cylinder head bore with a copper sealing washer (shim) of a certain thickness. A new shim with correct thickness must always be re-installed after removing injector. Measure thickness of injector shim. Shim thickness: .060 inch (1.5 mm).
  10.  
  11. Install new shim (washer) to bottom of injector. Apply light coating of clean engine oil to washer. This will keep washer in place during installation.
  12.  
  13. Install new O-ring to fuel injector. Apply small amount of clean engine oil to O-ring and injector bore.
  14.  
  15. Install injector into cylinder head with male (high-pressure) connector port facing the intake manifold. Push down on fuel injector mounting flange to engage O-ring and seat injector
  16.  
  17. Injector tightening sequence as follows:
    1. Install fuel injector hold down clamp (mounting flange) bolts. Be sure the clamp is perpendicular to the injector body. Do a preliminary tightening of these bolts to 44 inch lbs. (5 Nm). This preliminary tightening insures the fuel injector is seated and centered.
    2.  
    3. After tightening, relieve bolt torque, but leave both bolts threaded in place.
    4.  
    5. Install high-pressure connector and retaining nut. Do a preliminary tightening of nut to 11 ft. lbs. (15 Nm).
    6.  
    7. Alternately tighten injector hold down bolts to 71 inch lbs. (8 Nm).
    8.  
    9. Do a final tightening of the high-pressure connector and retaining nut. Tighten to 37 ft. lbs. (50 Nm).
    10.  

  18.  
  19. Install integrated gasket.
  20.  
  21. Connect injector solenoid wires and nuts to top of injectors. Tighten connector nuts to 11 in. lbs. (1.25 Nm).Be very careful not to overtighten these nuts as damage to fuel injector will occur.
  22.  
  23. Install exhaust rocker arm assembly.
  24.  
  25. Set exhaust valve lash.
  26.  
  27. Install fuel connector tube nut at cylinder head and tighten to 37 ft. lbs. (50 Nm). Be sure to use a secondary back-up wrench on the connector nut (fitting) while torquing fuel line fitting.
  28.  
  29. Install valve cover.
  30.  
  31. Install breather assembly.
  32.  
  33. Connect negative battery cables to both batteries.
  34.  

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 diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM.

 
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