BULLY DOG TECHNOLOGIES
UNCOMPROMISED DIESEL PERFORMANCE
STEP 3 BULLYBOOSTER INJECTORS
98.5-2002 DODGE 24V DIESEL P/N# 212100
Bill of Materials:
Injectors 		Tools you need:
8mm socket and end wrench
10mm socket
11mm deep well socket
15mm socket
19mm end wrench 		Other Recommended Parts
Performance Modules
Rapid Flow Filter & Exhaust
To order these call:
1-800-697-0194
Installation of Injectors
Read the disclaimer before installation
    NOTE: Prior to starting this installation :
  1. Wash engine around valve cover if it is dirty.
  2. Park vehicle (vehicle will be disabled until completion of installation).
  3. Engage parking brake; select neutral with standard transmission or park with automatic transmission.
  4. Remove keys from ignition and disconnect positive and negative battery terminals.
  1. Remove High Air Ram Intake.
  2. Remove the three 8mm injector line retaining bracket bolts.
  3. Loosen the 8mm rear injector line retaining bolt.
  4. Loosen the six 19mm fuel injector lines at the cylinder head. Slide the injector line nuts up the lines.
  5. Slide delivery tubes out ½ inch.
  6. Loosen the five valve cover bolts. Remove the valve cover, the valve cover bolts will stay in the cover.
    NOTE: It is not necessary to remove or loosen the rear injector retaining clamp bolts. The back hold on clamp is a slot.
  7. Remove the injector retaining clamp by pulling up and out.
  8. Thread one of the valve cover bolts into the top of each injector in turn and with the bent nose pliers, remove each injector while prying back slightly on the fuel line on outside of head going to the injector.
    NOTE: It is very important to take note when removing each injector whether the copper sealing washer is attached to the injector or has been left behind in the cylinder head. If the washer is in the cylinder head it must be removed. A flat head screw driver that will start into the copper washer but will not completely pass through it, may be used to remove the washer.
  9. Take each of the new injectors in turn and apply a slight amount of grease to the copper sealing washer. This will help hold the washers in position. Apply some oil to the rubber injector sealing rings.
  10. Each injector has a feed hole. This feed hole must face toward the fuel injector line when being installed. Press each injector in turn into the cylinder head while prying out slightly on the fuel cross over line. Prying down gently on the top of each injector will help seat the injector into the cylinder head.
  11. Install each injector retaining clamp in turn. It may be necessary to turn the injector slightly to allow the injector clamp to seat into position.
    NOTE: If any of the hold down clamps do not fit the injectors, the particular injector is probably 180 degrees off and must be removed and rotated.
  12. Once all the injector retaining clamps are in position, start the 8mm hold down bolts into the cylinder head. DO NOT TIGHTEN the 8mm hold down bolts at this time.
  13. Start the injector lines into the cylinder head. Tighten the injector line nuts hand tight. DO NOT TIGHTEN the 19mm injector line nuts at this time.
  14. Tighten the 8mm injector retaining clamp bolts to 89 inch-lbs.
  15. Tighten the 19mm injector line retaining nuts at this time.
  16. Install the valve cover at this time. The valve cover gasket can be re-used.
  17. Tighten the 8mm rear injector line retaining bolt.
  18. Install the three 10mm injector line retaining bracket bolts.
  19. Make sure all tools are removed from the engine compartment and reconnect the battery terminals.
  20. Turn the ignition key to the start position just enough to bump the engine and turn the ignition key back to the off position. You will hear the electric lift pump. Repeat this process 3-4 times to help bleed the air out of the system.
  21. Crank engine holding the throttle pedal down about halfway. If the engine does not start within 30 seconds, stop cranking. Allow the starter motor to cool down and then repeat. The engine will usually restart within a few seconds. Upon start up, the engine will probably run rough until any remaining air bubbles are evacuated from the injector lines. Check for leaks.
  22. Enjoy!