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Old Nov 23, 2006 | 01:29 PM
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Question Injectors

Just wanting to know if replacing an injector is easy on 02 psd? How long does it take?
 
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Old Nov 23, 2006 | 01:46 PM
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Kwikkordead
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This is how I did mine. Copied and pasted from THIS THREAD.

11:00 am
I brought the truck in and pulled the valve covers, removed the gaskets and the wiring harness's.
I pulled both rear injectors and let the oil and fuel run down into the cylinder. I thought that just putting a shop towel over the hole would deflect the oil that comes back up through the injector hole. I rolled under the truck and proceeded to turn over the engine by hand and immediatly noticed that the oil came out with enough force to blow the rag out of the way and soak the air conditioner. UGH. (Stuff a ton of rags on top of the air conditioner unit.)
Ok, that hurdle is over; pull the rest of the injectors. Routine job.
The tips of the old injectors didn't appear to be that worn out, but they were sure making a lot of noise during operation.
Remove the oil deflector tubes using a 5mm allen and the 3/8" impact gun.
Install them on the new injectors, leave them a touch loose for the final adjustment later.
Remove all the glow plugs.
Install all the new injectors.
Torque them to 120 inch pounds.
Roll under the truck again and turn over the engine for two complete cycles ( 4 crankshaft revolutions) NO LESS. More if you hear oil spurting out of the glow plug holes.
Position some cardboard over the cylinder heads to deflect any flying oil.
Crank the engine over (no load on the starter with the glow plugs out) to fill the HPOP rail. This requires a couple of minutes total crank times. Don't do it all at once or you'll bake the starter. 30 seconds, go clean up your tools for 5 minutes and then come back and crank for another 30 seconds. Repeat a couple of times.
Remove the cardboard.
Install the glow plugs. I had a full set of Bosch part number 80 033 ( OEM ) glow plugs that I purchaced a couple of weeks ago to install along with the injectors.
Reinstall the valve covers, boost tubes, reconnect whatever sensors, connectors that were removed to gain access.
4:00 PM
I cranked on the starter for about 15 seconds and it fired with a big cloud of smoke.
 
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Old Nov 23, 2006 | 02:22 PM
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Thank you it sounds pretty straight forward. Does not seem to take alot of time. It is nice to know what to expect if there is an injector bad. Planning trip across country so cannot have it sluggish up hills or take chance on ruining motor or internal parts.
 
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Old Nov 23, 2006 | 02:31 PM
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Just make sure that you get the copper washers out from the bottom of the injector sleeve, the hold down brackets in the proper position when torqueing them down, and the residual oil out of the cylinders before you seal them up. It's easiest to do the final clearing with the glow plugs removed because you can crank it over with the starter motor. Lay something across the top of the engine to catch the spray or you'll be cleaning oil mist of off EVERYTHING. It comes out of there like a pressure washer when cranking. Whatever you do don't use Autolite glow plugs, they break off and fall in. Use only Bosch, Beru, or Motorcraft.
 
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