Dodge Ram Truck 1500-2500-3500. Manual - part 1486

OPERATION

The Fuel Control Actuator (FCA) is an electronically controlled solenoid valve. The ECM controls the amount of fuel
that enters the high-pressure pumping chambers by opening and closing the FCA based on a demanded fuel pres-
sure. When the FCA is opened, the maximum amount of fuel is being supplied to the fuel injection pump. Any fuel
that does not enter the injection pump is directed to the cascade overflow valve. The cascade overflow valve reg-
ulates how much excess fuel is used for lubrication of the pump and how much is returned to the fuel tank through
the drain manifold.

An audible click from the FCA is normal when operating the key from the ON to the OFF position.

REMOVAL

The Fuel Control Actuator (FCA) is a non-servicable part.

INJECTOR - FUEL (EARLY)

DESCRIPTION

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.

CAUTION: Two different fuel injectors are used (early and late). Although they physically look the same,
they are NOT interchangeable. Be sure to reference the injector part number when replacing a fuel injector.
This part number is laser-burned onto the injector. Failure to replace with the proper injector will cause
severe engine damage.

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FUEL INJECTION - DIESEL

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OPERATION

High-pressure fuel is supplied from the injection pump, through a high-pressure fuel line, into a fuel rail, through
high-pressure lines, through steel connectors and into the solenoid actuated fuel injector. The ECM actuates the
solenoid causing the needle valve to rise and fuel flows through the spray holes in the nozzle tip into the combus-
tion chamber.

Each fuel injector is connected to the fuel rail by a high-pressure fuel line and a steel connector. This steel con-
nector is positioned into the cylinder head and sealed with an o-ring. The connector is retained in the cylinder head
by a nut (fitting) that is threaded into the cylinder head.

The torquing force of this threaded nut (fitting) provides a sealing pressure between the fuel line connector and the
fuel injector. Retaining nut torque is very critical. If the nut (fitting) is under torqued, the mating surfaces will not
seal and a high-pressure fuel leak will result. If the fitting is over torqued, the connector and injector will deform and
also cause a high-pressure fuel leak. This leak will be inside the cylinder head and will not be visible. The result will
be a possible fuel injector miss-fire and low power, or a no-start condition.

The fuel injectors use hole type nozzles. High-pressure flows into the side of the injector, the ECM activates the
solenoid causing the injector needle to lift and fuel to be injected. The clearances in the nozzle bore are extremely
small and any dirt or contaminants will cause the injector to stick. Because of this, it is very important to do a
thorough cleaning of any lines before opening up any fuel system component. Always cover or cap any open fuel
connections before a fuel system repair is performed.

Each fuel injector connector tube contains an edge filter that is designed to break up small contaminants before
entering the fuel injector. The edge filters are not a substitute for proper cleaning and covering of all fuel
system components during repair.

The bottom of each fuel injector is sealed to the cylinder head with a 1.5mm thick copper shim (gasket). The correct
thickness shim must always be re-installed after removing an injector.

Fuel pressure in the injector circuit decreases after injection. The injector needle valve is immediately closed and
fuel flow into the combustion chamber is stopped. Exhaust gases are prevented from entering the injector nozzle by
the needle valve.

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FUEL INJECTION - DIESEL

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REMOVAL

CAUTION: Refer to Cleaning Fuel System Parts.

1. Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables.

2. Remove breather assembly.

3. Remove valve cover. Refer to Engines for procedures.

4. Remove necessary high pressure fuel line connecting necessary fuel injector rail to high pressure connector.

Refer to Fuel Line Removal for procedures.

5. A connector retainer (nut) is used on each connector tube. Remove this nut(s) by unthreading from cylinder

head.

6. Using special high-pressure connector removal tool #9015 , or remove necessary high-pressure connector(s)

from cylinder head. Tool #9015 threads onto connector tube. Use tool to pry connector tube(s) from cylinder
head.

7. Remove necessary exhaust rocker arm assembly(s).

8. Disconnect injector solenoid wire nuts at top of injectors.

9. Remove 2 fuel injector hold-down clamp bolts at each injector being removed.

10. USING TOOL #9010:

a. 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.

b. The rocker housing is bolted to the top of cylinder head. The mounting stud from tool #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 3 rocker housing support bridges.

c. Install and tighten 2–piece mounting stud to rocker housing. If removing the #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.

d. Position tool handle to mounting stud and install handle nut. Leave handle nut loose to allow a pivoting

action.

e. 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.

f. Slide the retainer sleeve over pivoting handle head to lock clamshell halves together.

g. Be sure handle pivot nut is loose.

h. Depress handle downward to remove fuel injector straight up from cylinder head bore.

11. Remove and discard injector sealing washer. This should be located on tip of injector or.

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