1985 F250 4x4 6.9 IDI Injector removal/install.

Put in new injectors today, what a difference, runs like a new truck and will actually idle without shaking your teeth out of your head. I started to get extra white smoke and a rough idle, I changed the fuel filter and it helped for a little while, added diesel kleene to the filter and the fuel tank and it also helped a little but the injectors were originals with over 150k so it was time to change them..... Runs great now, gonna grab some fresh glow plugs as one of the electrical contacts broke off the top when I was trying to put the wire back on, I know they aren't original put they look OLD.

Here's the eye candy, not very exciting as far as project stuff, but hey it's neccissary maintenance.


Took off air cleaner and plastic hose.


Took off plate on front of intake that holds the trottle cable (it has two bolts holding it to the front of the round part)


used 5/8 open end to remove high pressure fuel lines (I had previously take off the clamps and rubber that hold them in sets of 3) I loosen the tops off all the injectors first but leave them on hand tight to keep them as clean as possible, I then loosen the end connected to the injection pump and remove them one at a time setting them on a clean rag. You can label them iof you want but they are all bent specific and really can't be put on wrong. You can see I have the new injector in the front right of the picture. I left the plastic cap that came on it on top to prevent anything from getting inside it. I also left the two high pressure fuel lines that you can see in the picture since they are attached to what is the bottom portion of the injection pump and are a pain in the butt to get at so I just worked around them.


New clean shiny injector on left, original old dirty injector on right. The new injectors were oily/greasy enough that the coppor washer stayed seated to it even when I was placing them into the heads, you can use a small dab of grease to hold them onto the injector so you don't drop them into the head and or engine compartment. I also used anti seize on the injector threads for lubrication and so that they will someday come out more easily (hopefully that won't be for another 150k miles...)

One thing people also warned me about was 1. making sure the old copper washer from the old injector came out and to retreive it if it was still in the head, and 2. make sure that where the copper washer sits is clean before installing the new injectors. Mine all came out on the old injectors which was nice.


Old vs. new


All the new injectors are in with plastic caps on, I was able to leave the caps on while I tightened them with the torque wrench.


I am **** and torque stuff twice to make sure it doesn't get over torqued, The new injectors said 35 foot pounds, so I started at 30 did them all, then cranked it to 35 and did them all again, the anti seize made this super easy.


Round 2


Since I just replaced all the return caps and retuirn fuel lines and the injectors came with new O-rings I just snapped all the return fuel stuff back over then new injectors, which made it super easy, it also made the 54 dollar install kit I got go back to the store! I like to push them down and twist a little to make sure they are seated on the O-rings properly.


High pressure lines go back in one at a time, I thread the end onto the injection pump first finger tight, then the injector finger tight, then I use the 5/8 open end on the injector pump and and snug it up before I go to the next injector. I leave all the tops hand tight and tighten them last when all the high pressure lines are on. Like I said before they reall only go in one way so you can't really put them onm the wrong nipple on either end.


I put on a new filter any time I mess with the injectors or the pump, I added a little diesel kleene to the filter and filled it the rest of the way with fresh diesel.


As soon as i got the new filter on and put on the air cleaner assembly it started to downpour and hail....

Don't for get to reattach the trottle cable plate and clip the throttle cable back onto the Injector Pump. It fired right up after a couple of cranks to fill the empty high pressure lines and now she purrs like a kitten and when you foot down she goes like a raped ape, revs nice, and no more white smoke!

Easy job and not too bad on price, I paid 35 bucks an injector which is more expensive than can be found online but there was no core charge, they came with copper washers and orings installed and I have a 3 year 36000 mile no questions asked exchange warranty, which is what sold me. Hopefully I won't need it but it's nice to know I have the option.

Now if it will only stop raining I can put the dash back into the truck.....

Mason