Dodge Cummins injector solenoid removal

Solenoid replacement

[@yorkielover6257]

I want to share my story. 03 Dodge ram 2500 Cummins diesel 5.9. Smarty programmer says P2019 code, bank 2 #4 injector. I called my local stealership and got a price on 6 injectors and labor. $8400! Almost what I make in a year on social security. Took a 1 1/16 deep well socket and turned it down in an old Logan lathe I bought 30 years ago. Took off all injector wires and checked ohms. Every harness read 0 ohms. Checked every injector all read 0 except #4, read 12 ohms. Bought a solenoid on Amazon for $28. O-rings came with solenoid. Checked it, read 0 ohms so I installed it. Truck runs perfect again. Without your video, I would not have had the guts to fix it myself. Many thanks man, for saving me a ton of money!

[@Hiperf]

Super glad everything worked out for you. I was nervous about something falling in the engine but if you take your time and be slow everything will go ok. Glad you saved a bunch of money.

[@luisuranga9212]

Did you removed the fuel injector to remove the solenoid? I have kinda the same problem 2005 3500 Cummins

[@yorkielover6257]

@@luisuranga9212 no. Actually the removal and reinstall was quite simple. Bought the solenoid on Amazon for $28. The stealership wanted over $5000. Laughable!

[@luisuranga9212]

@@yorkielover6257 thank you for you help I just ordered the solenoid on Amazon like 45 bucks 👍👍

[@yorkielover6257]

I know when the solenoid fails, the Cummins goes into limp mode, it shuts off the other 2 injectors, therefore you have 3 dead cylinders. Imagine trying to drive the 4 door pickup, with 8 ft bed, with 135 gallon fuel tank in the bed plus 35 gallons in the original tank, on just 3 cylinders. Believe me a kid on a bicycle could pass you on the shoulder. My 2003 has 1.3 million miles and this was the first problem I had with the truck since 2005 when I bought it used. This truck has served me well. Since I retired living on SS at $11k a year, I may have to sell it. Under Bidenflation, fuel is almost $6 a gallon, I can't afford to drive it. While my truck sits in the barn, I get around using my 2008 Prius getting 52 mpg consistently..

[@michaelschnetzer2284]

Seems like #3 is a popular one to go out for some reason. I had this same issue with my pickup and after a Google search, seems preety common for that injector/solenoid to go out for some reason; don't know if location/heat...? Anyways, great video, I will be doing this soon on my #3 injector. Your video did EXACTLY what I was looking for!

[@Hiperf]

I did learn that fuel does flow through this body to cool down the solenoid so the fuel in the solenoid body is normal. You also need to make sure your top is directing ok for the wiring before torquing. I have changed 5 of these now for family and friends. Seems they are a problem between 05-07. They wear out and you can see arching on the solenoid body.

[@darrenjayce2633]

I know I'm pretty off topic but does anybody know a good website to stream new series online?

[@Jeremyandroid]

Thank you for this. I try to do all my own work on my Cummins as well.

[@Hiperf]

9 months later i had the exact same issue but with #6. This time i just changed the solenoid.

[@Jerry-kb2bu]

thank you for the video, been searching for this exact issue.very happy that it can be done in the truck

[@Hiperf]

Yes it definitely can be done in the truck. Just be careful when the nut ready to come off of the threads from the injector you treat it like you are defusing a bomb so nothing bumps that small spring. Same caution going back on with the solenoid. I took the spring off after my hands were clear just to sure when i was climbing back off the truck i didn't rock the truck to knock the spring off. Its really a simple job.

[@fattmouth7715]

Use a can of brake clean with the straw . Spray though the tip with the plunger removed , then check the spray pattern . Works great 😎

[@yorkielover6257]

This video is perfect! The only one I found to do all I wanted to do. 👍

[@jeepslivin]

added note..there is a check ball that can come unseated once the spring is unloaded. drain the fuel from the rail. if you dont as you unscrew the solenoid fuel will cascade out and can unseat the check ball. i learned the hard way..

[@Hiperf]

Roger Livingston is this ball under the spring? Core injector basically so I removed the spring and held it upside down carefully and nothing fell out. ?

[@Hiperf]

I see exactly what you were talking about. I have the same problem again but now its #6. My plan is to change just the solenoid so I pulled that injector out and and removed the solenoid. I pulled that piece out of the injector and saw that very very very tiny little ball that seats at the bottom. Wow that thing is small. Easy to loose or not even know is there! I don't plan to go that far again though. Thanks for the info!

[@23firecat23]

@@Hiperf was you able to do this inside the truck without unseating the check ball?

[@overheadcam32]

@@Hiperf I just ordered 50hp over injectors for my 2006 ram. I also used to make biofuel years ago. Ran 100% at times. I thought it was neat to find another cummins owner doing the biofuel. What happened to your KZbin channel? Not doing diesel related content. Thanks.

[@Hiperf]

@@overheadcam32 I typically post stuff when I'm out in the garage doing something I can't find information on with KZbin. Figured it might help somebody out there. Haven't had to work on anything lately minus a 1845c last fall but KZbin would have probably kicked it off with the language that came out of that learning curve.

[@Hiperf]

I have enough core injectors laying around so if anyone is still interested in answers to all these questions I can do another video better showing everything in detail the best I can.

[@dwaynemaddog5637]

Thank you for the video .

[@johnstark3058]

So I have one that ohm check zero, no codes either, truck ran decent but had a slight fuel knock, replaced injector, and now I'm thinking ordering a new solenoid for my old one

[@Hiperf]

I definitely would.

[@johnkoch6230]

I ordered a solenoid from e-bay and it has a threaded hole in the top of it? original does not!! Any Ideas,,btw VERY Informative Video thank you so much

[@Hiperf]

Not sure. My had the 2 terminals on top. It was a solid unit. What was the Ebay auction number

[@johnkoch6230]

@@Hiperf 353249451758,, it clearly looks like there should be clip on top

[@TonyBushmin]

Where did you order o rings and are the ball and set screw on top and you just swap it over?

[@Hiperf]

I just broke the nut loose and spun the whole top right off. If you leave that little spring there what you are left with is the bad solenoid and the nut. It's on there snug but you need to slide the nut off of the old solenoid and back on the new solenoid with some lubrication. Then reinstall. Make sure you hand tighten first and adjust the solenoid properly so your wires line up the same.

[@sergioquevedo8958]

Were did you get the orings from im have the exact problem and dont want to expend to much money

[@Hiperf]

Sorry. I never had any notification that you commented. You probably have it figured out by now but my new solenoid with no orings. I just lubricated and used the same orings since they stay with the nut. Nothing leaked. Probably isn't the best choice but i have 25k miles now and my oil doesn't come up any. Nothing is leaking in my case.

[@aintright3889]

Why on our 06/07s it's always the #3 sometimes the #2 injector solenoid that takes a dump on us? Has anyone questioned that? Thanks for the great Video :)

[@j.c.316]

Working on my #2 solenoid at 135k miles.

[@yorkielover6257]

Always look for the bright side to a situation. I would much rather be working on injector 3 in the middle than #6 buried under the firewall.....

[@luisuranga9212]

How do can know if is the solenoid or the fuel injector, I have a 2005 3500 and I lost power at the freeway

[@Hiperf]

You can test the solenoid by checking the OHMs.

[@derrikrussell1074]

so it doesn't matter which wire goes to which side of the solenoid?

[@Hiperf]

No but they kind of reach where they need to go. The wires keep their memory when you remove the gasket

[@JosephHoro-mg5ox]

please you can so me what is function of solenoid of injector.

[@Hiperf]

It fires the injector from the ecm voltage signal. Without it, it wouldn't do anything.

[@honeywellsnake]

Can't figure it out in the video but what size 12 point socket do I need.

[@Hiperf]

I took a 1" - 12 point and used a dremel and took down the nipples enough where it grabbed the injector nut

[@honeywellsnake]

@@Hiperf so is it bigger than a 1 inch then? 1 1/8?

[@honeywellsnake]

@@Hiperf or are you talking about the posts when you say nipple?

[@Hiperf]

@@honeywellsnake I think 1-1/8 will be too big.

[@Hiperf]

@@honeywellsnake what's your email. I will send you a picture

[@novarocker247]

Where did you order from. I want a Bosch solenoid

[@Hiperf]

I ordered mine off ebay. I was in a rush to get the truck going and I contacted them and paid to fly it Saturday nda. Mine was not Bosch. I was fine with that. Something internal and I probably wouldn't have trusted it but this is just an electronic piece. No harm if it goes back out.

[@novarocker247]

@@Hiperf I can’t seem to find Bosch ones but they have to be getting them from somewhere. I’m an idiot and snapped the post off new injector.

[@Hiperf]

@@novarocker247 It happens. I wouldn't be concerned about throwing an aftermarket on it. Who knows who Bosch buys from. It's probably someone in Germany.

[@Hiperf]

Didn't verify it 100% for fitment but a quick check and I found this ebay auction lot #143904316281 Says oem Bosch.

[@novarocker247]

@@Hiperf I appreciate the help. It’s what I get for using an electric ratchet. Took it right off.