Can anyone point me in the right direction? Maybe some links or some tips would be awesome. I will be swapping out my stock early '99 injectors for Casserly Stage 2 Single Shots. I will be doing this at a friends house up north and will have to tow my travel trailer back home so I can't afford any problems. Thanks in advance guys

 

Easy... There are a couple ways of doing this. The way I like to do is removing one injector at a time and swapping them in one motion. That way the least amount of fuel and oil enter in the motor.

-Remove intercooler tubes
-valve covers
-unhook valve cover harness and remove from glowplugs/injectors
-Remove lower holddown injector bolt...and slide the holddown towards the center of the motor...
-Lube up and install all Orings on new set of injectors. You might want to dab some grease on the copper washers just incase they don't want to stay on. You don't want to have to fish these out later...if they fall off.
-Then with a small prybar or a very large allen wrench. place under the injector holddown and pop/slide out the injector. Don't screw up the rocker arms or push rods.. LOL
-While you are pulling the injector out place the new one in. All in one motion. Make sure you dip them in oil or lube them up before you install them. Pay attention to the old injector to make sure the copper washer is on it and didn't stay in the injector cup.
-Push it in by hand and give it a few taps with the palm of your hand. You may need to give it a tap or two with a rubber hammer.. you will hear it sound solid once the injector is all the way down. Then stick the bolt in and torque to 120 in-lbs
-Do this on all (4) injectors on one side.
-Remove all (4) glow plugs. Once you get the glow plugs loosened use a short section of 3/8" fuel line that fits over the glow plug perfectly and use that to thread it out of the block.
-Take a straight edge and place it over all the injectors at once to make sure they are all flat!! If one is high then chances are it isn't seated properly.
-Install the valve cover with NO VALVE cover harness and don't plug anything in.
-Do the same thing on the other side.
-Go under the truck and use a large breaker bar and turn the motor over by hand 10-12 times. This will push all the fuel and oil out of the glow plug holes. Make sure you valve covers are on.. LOL you only need a couple bolts...
-Then get behind the wheel and try to start it for 15 seconds... do this about two times. This will clean everything else out. It will sound real funny trying to turn over...LOL
-Then remove the valve covers and install the glow plugs. Use the 3/8" line to thread them in. Then torque them down... 15 ft-lbs
-install the valve cover harness and plug everything in.
-Then finish installing everything and start it up... it will take some time to get the air out. I like to go in about 15-20 second intervals trying to start it... anything more and the starter doesn't like it...
-It will run rough for a little while... and take her for a spin. Go blow your first boot...LOL


I am sure there are a few minor things I missed... Let me know when you plan on doing this... I might be available... LOL

 

Layson has great info. The way I did it was to have 3 paper towels sitting ready to go for each injector, or at least the first one. As soon as you yank the injector, stuff paper towel #1 in. It will immediately saturate with oil. Pull it out and stuff # 2 in. Pull it out and stuff # 3 in. That should grab 90% of the oil that was about to run down into the cyl.

I like to spray a blast of brake cleaner down the injector cup to blast any grime or debris out of the way of the new injector seating as well....

When you're all buttoned up, you'e supposed to drive it at 3000 plus RPM's for 10 mins to work the air out of the high pressure rails. I did and it worked well.

 

I made a video on how to do this.........

 

Remove the valve covers, then pull the oil plugs. They are located between the #1 & #3, #5 & #7, #2 & #4 and #6 & #8 injectors.



Be very careful with them, they are 1/8" allen heads. Do not use a key, use a SOCKET. Put it in the hole, and rap on it a few times. Then loosen.



Here is a picture of one that I stripped, then had to hammer a 1 size larger torx bit into in order to extract it.




While those are draining, un hook all of the injectors, and use one finger to pull up on the white wire (glow plug wire). It will just pop off. Remove reuseable gasket.



Make sure this copper washer is still on the injector and not down in the injector cup.


Then use a deep well 10mm 1/4" drive socket to remove the glow plugs.

*BONUS TIP!!!!***
After you get the glow plug loose with the 10mm switch to an 11mm and it will not get bound up under the pushrod. *Some 1/4" drive deep 10mm's will get stuck, others will not.


Reinstalling Injectors...


With the glow plugs out, the oil plugs in, the injectors in - this is how I purged the cylinders.

 

Clay, I've also heard that you can park with the nose up or jack the front up, pull the rear injector from each side, and let it sit that way for 10 minutes or so to let all the fuel/oil drain into only the rear cyls.

 

Thats a great post Maintain. Reps to you.

 

Yeah, Marty has some cool videos.

 

Hey Rick,
What happened to Scotty's(dodge boy) video of your injector install?

 

We pulled the last injectors on Rick's (miller_feed), let it drain, and then used my Superduty Sucker to remove the oil from the cylinders and around the glow plugs. I did put the suction pipe of the Sucker in the hole as it was draining also.There very little oil coming out the glow plug holes after the injectors were in and we turned it over by hand. We put rags over the holes and they didn't get much oil on them.

 

. I can't seem to download it to my puter. Something about his camera.