Just replaced Bad Injector Solenoid on my 2007 Dodge diesel 5.9 H.O.! Quick fix!

[HerbW]

Hi guys,
My 3500 Mega truck is fixed and getting 20 MPGs now! I had engine trouble and it turned out to be #4 injector was open. I bought an injector solenoid on Ebay for my truck. I was able to field replace it. Well actually I did it in my pole barn. LOL

1. First I removed the two rocker assemblies and the two wires to the bad solenoid which was #4. The little connection nuts are fastened to the wires! Nice!
2. I put a shop towel around the push rods in case something flies it doesn't go in the engine.
3. I used a pair of parallel pliers under the valve cover gasket to break loose the nut on the solenoid mounted on the injector top. I did this only because I couldn't find any socket to fit. I was told by "experts" it is a special size. I'll never do again as I have the socket now.
4. I carefully removed the bad solenoid and nut off the injector. While off I went to auto parts house and discovered that a 12 point 1 1/16th inch deep wheel socket will fit the solenoid nut. Pay attention to the little spring in the middle of the injector that you don't knock it off while the solenoid is off.
5. Make sure your o rings are in right order and go for it. I put the solenoid nut on the new one and carefully set it over the injector and screwed it down. I then tightened it 15 Ft Lbs using 12 point socket. The socket fits a little sloppy but worked great! MUST be a 12 point!
6. I reassembled everything where it came from. I checked the valve lash while there! Why not! I then installed the valve cover.
7. The truck cleared all my trouble codes and runs great again!
8. Total cost was less than $100! I also bought a Torks Tool injector nozzle remover just in case in that Hundred Bucks! Check it out on Youtube!
9. Today I removed the valve cover to make sure I didn't have any fuel leaks on the injector top to end up in the engine oil. It didn't have any! Email me with any questions.
10. Enjoy life and keep your money! Tech fix was going to be $1000.00! I could do one in a half hour now and so can you!

 

[jelag]

Wow, this was an interesting post.... thanks for sharing

 

[jtsaz]

I am currently attempting to do the same thing on my 07 where did the 2 orings go? I see one on the inside of the retaining nut though I dont see a second one anywhere when I pulled off the original one. Also the solenoid came with an exploded view sheet and they circled what looks like a ball and a set screw and circled it and wrote "these must be swapped out" did you have to do this on yours?

 

[JJPage]

Thanks Herb, good info!

 

[HerbW]

I am currently attempting to do the same thing on my 07 where did the 2 orings go? I see one on the inside of the retaining nut though I dont see a second one anywhere when I pulled off the original one. Also the solenoid came with an exploded view sheet and they circled what looks like a ball and a set screw and circled it and wrote "these must be swapped out" did you have to do this on yours?

I was lucky. The one I changed out had the ball and set screw already in it. The two new solenoids would need changed out. I threw away the old solenoid. I would love to dis-assemble it and see how it fits and know the set screw size. One o ring is in the nut. One in the top in an indent and the lower one is one the injector body as I recall that the nut slides over. You can see both in the center of the attached photo. I've attached a different picture I saved to give you a better idea. I coated the sides of the new solenoid with a light coat of vasoline to help it move easier. Make sure you don't loose the injector spring that stays on the top of the injector.
Let me know if you need more help. Herb

 

[chipster]

would you mind sharing where you got the solenoid ??? PLEASE.

 

[HerbW]

There are two solenoid sellers now on EBay. The one that includes the o-rings needs the ball and screw moved from your old one. They are Bosch type. Nice! The other company sells without new o-rings but are ready to install using existing o-rings. The ball and screw already in place. After installing new solenoid, start your engine either way with the valve cover off and watch for any fuel leaks on the solenoid nut. I don't expect any but the engine oil stays put and nice to see it's not leaking diesel before the valve cover goes on. The nut is pretty snug on the solenoid in two spots. Let me know if you can't find the solenoid on EBay. I looked it up as Dodge injector solenoid I believe. At about 72 bucks each is a bargain! I hope the bad one is cylinder 1-4 where vision is better on the first run. Be sure to lift off straight up the old one and don't knock off spring. I'll sell you one if you don't find any for sale. Good luck, Herb

 

[HerbW]

Hi. I just changed out another bad solenoid. The little hex nut in the top of the solenoid holding a ball bearing used a 2.5 MM hex wrench and was very tight in there. The two nuts on the solenoid are 8 MM socket sized. Did this one in less than half an hour!

 

[HerbW]

I'm making a travel kit with an injector solenoid, allen wrench for solenoid nut, the socket to pull off the solenoid nut and the tools to do it with. I could field fix if it gets me again. Maybe if you're in Oregon or southern Washington, I could help you.

 

[CKelley1]

good writeup, i took a 1" socket and used a dremmel to make a better fit.