Injector Removal ??
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From: Kamloops, BC
Injector Removal ??
I'm trying to get the injectors out.... Am I missing something ?? I undid the hold down bolt at the bottom centre of injector, but can't get it out of the hole and I can't remember if you have to pry it out or not.. I thought they should just slip out !
Post Fiend
Joined: Feb 2007
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From: Dallas-Ft. Worth
The bracket under the injector has a key hole slot in it that locks on another bolt under the injector. You'll have to hold the bracket out and pry up on it at the same time. They'll pop loose.
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Did you pull the oil defletor off the injector? Yes you will need to use a small pry bar but it should not take very much force. And you pulled the bottom injector bolt not the top rite? Once the injector is loose the hold down will just pop over the top bolt and out comes the injector.
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From: Kamloops, BC
Ya.. just took out the bottom bolt ! What about the oil deflector ?? I can't remember taking that off before on the other motor.. actually it is still attached to the injector that I'm putting back in !
Post Fiend
Joined: Feb 2007
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From: Dallas-Ft. Worth
I didn't take the spouts off mine either. Until after I put 'em on the new injectors, of course.
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From: Kamloops, BC
I got it guys... Just took a little more force ! Thanks.. I just didn't want to wreck anything.. I've wrecked enough lately ! lol ! Happy Boxing day ! Thanks for the help !
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From: Kamloops, BC
next question..... Do you have to get all the oil out of that cyl.. or is it just the injector cup.. The cup itself doesn't have any oil in it to speak of... And why would you have to empty the whole cyl.. if you are just taking an injector out and putting another one in ?? May have found the problem with number 8... the o-rings are toast and in pieces !
Fleet Owner
Joined: Jun 2004
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From: Rio Rico, AZ.
I copied, pasted my injector procedure from another thread of mine.
Yes you need to get all of the oil out or you will hydrolock the engine.
Severe damage may occur if you attempt to start the engine when the cylinders have too much oil in them!
Yes you need to get all of the oil out or you will hydrolock the engine.
Severe damage may occur if you attempt to start the engine when the cylinders have too much oil in them!
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.
.
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.
.
More Turbo
Joined: May 2006
Posts: 504
Likes: 1
From: Victoria BC, Canada
Yes, you need to remove all the oil from the Cyl, because as soon as you pull the old injector the oil from the gallery's in the Cylinder Head will drain down the Injector tube into the chamber.
Remember to put the Valve cover on with the injectors out and turn over the motor with a breaker bar, nice and slow.
Once you install the new injectors (Don't forget the copper gasket/washer on the end of the injector), (After getting oil out of chambers) and everything is back together then check oil level.
Remember to put the Valve cover on with the injectors out and turn over the motor with a breaker bar, nice and slow.
Once you install the new injectors (Don't forget the copper gasket/washer on the end of the injector), (After getting oil out of chambers) and everything is back together then check oil level.
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Posting Guru
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From: Kamloops, BC
So without making a big mess... whats the best way to get all the oil out of the cyl... put the valve cover over it and turn it over a few times ??? Will it then just run back down the injector holes ?? Put the injectors in and leave the glow plugs out and then turn it over with the injectors in ??? Sorry for all the ques.. I think I'm in over my head today and I have to get this thing running by tonight !
Thread Starter
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Posting Guru
Joined: Jul 2004
Posts: 1,235
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From: Kamloops, BC
Yes, you need to remove all the oil from the Cyl, because as soon as you pull the old injector the oil from the gallery's in the Cylinder Head will drain down the Injector tube into the chamber.
Remember to put the Valve cover on with the injectors out and turn over the motor with a breaker bar, nice and slow.
Once you install the new injectors (Don't forget the copper gasket/washer on the end of the injector), (After getting oil out of chambers) and everything is back together then check oil level.
Remember to put the Valve cover on with the injectors out and turn over the motor with a breaker bar, nice and slow.
Once you install the new injectors (Don't forget the copper gasket/washer on the end of the injector), (After getting oil out of chambers) and everything is back together then check oil level.
I think I could you your help if you can make it John ! Thanks for the advise though !
More Turbo
Joined: May 2006
Posts: 504
Likes: 1
From: Victoria BC, Canada
How far along are you now? Let me see what I can work out here for the kiddies, wife is going to spend more $$$ today...