Injector install procedure with photos

[lmills]

125 for the injector puller and 10 for the injector tube puller.

 

[Matt400]

Remove valve cover

First I have to say. . great write up! and thanks a bunch for taking time to do it.



When you pulled the VC did you happen to notice a spring that sandwiches between the cover and the rocker assembly? I have not figured out what thats for yet.

#ad

 

[RankRam]

Matt when I adjusted my valves, I noticed the spring too. My guess is it's some kind of noise/vibration dampener?????

 

[blacksheep4x4]

Miller special tools, 1 800 801-5420. They take credit cards.

And no, there should not be any residual pressure after being shut off for a minute.

Will tjese tools work to remove the 06 injectors. I didn't know if they changed the injectors or not. BTW I called the numer that was posted and talked to thier tech dept and they said they don't make or supply tools to work on 06 cummins. I don't think he realized I was talking about the cummins in the Dodge pickup. I'll try to call again.

 

[TCluff]

GREAT WRITE UP, I REALLY LIKE THE IDEA OF STRESSING THE USE OF TORQUE WRENCHES, MOST MECHANICS JUST WRENCH AWAY WITHOUT CARE OR KNOWLEDGE NOT EVEN KNOWING THE RISKS THEY ARE TAKING, ALL I CAN SAY IS GOOD JOB FOR YOU AND EVERYONE ELSE THAT POSTED WITHOUT ARGUMENTS OR NEGATIVE COMMENTS

 

[GWoody]

spring

First I have to say. . great write up! and thanks a bunch for taking time to do it.



When you pulled the VC did you happen to notice a spring that sandwiches between the cover and the rocker assembly? I have not figured out what thats for yet.

#ad

I read or someone told me the springs only purpose was to insure the cover is grounded, might be so, probably wouldn't ground well through the gasket and if memory serves me correctly I think there are o rings on the bolts that hold the cover on.

 

[Matt400]

I read or someone told me the springs only purpose was to insure the cover is grounded, might be so, probably wouldn't ground well through the gasket and if memory serves me correctly I think there are o rings on the bolts that hold the cover on.

Hrmm... could be, but I wonder why they would need the cover grounded.

 

[sag2]

I'm sure I recall the instructor mentioning in class that the spring was there for grounding. Since the VC gasket and the rubber o'rings on the bolts keep the cover from making good contact, they add the spring to be sure it makes a good ground. Keeps the RFI (radio frequency interference) problems from striking.

 

[Matt400]

I guess that would make sense with the high voltage injector circuit under the cover, thanks for the info.

 

[RankRam]

Thanks Sag2!!

 

[CraigJones]

I'm going to have my injectors taken out and cleaned the dealership is telling me to becarefull of a small ball that can fall out when removing the injectors. Does anybody no where this ball is and when to look for this small ball ? Is replacing the injectors the same in my 2003 compared to a 1998-2001 ? My buddy has done this a bunch of times I just want to know if there's anything to point out to him that might be different. Thanks Guys.

 

[rbattelle]

My buddy has done this a bunch of times I just want to know if there's anything to point out to him that might be different. Thanks Guys.

As far as I'm concerned, it couldn't be any more different than changing 2nd gen injectors! You should study this thread.



-Ryan

 

[Diesel Power]

one thing that is missing in this thread that i did not see was to suck the leaking fuel from the injectors out of the piston before reassembly, other wise it wont start up easily :-laf

 

[nickleinonen]

very nice writeup indeed...

 

[JStieger]

Sag2-



If you don't remove the injector, but just the connector tube, can you just go straight to the 37 ft-lbs torque spec?



Or do you still have to loosen the injector hold downs and do the 2 stage torque-down (11 ft-lbs then 37 ft-lbs)?



Thanks!

 

[Vaughn MacKenzie]

JStieger you should be able to go straight to 37 if the injetor wasn't disturbed. Doing 2 stages if everything was removed just helps to make sure the tube gets seated back perfectly into the injector port, but if you didn't touch the injectors just go ahead and torque the fuel line nut down.

 

[JStieger]

Vaughn-



Thanks - that's just what I thought! I was initially thinking that I might have a #2 connector tube leak judging from the moisture around the head and intake manifold in this area, but I wiped the area down with a Q-tip after I posted the question. The Q-tip came back black like soot and I smelled it - no diesel - and my rail pressure is good with no low pressures. Looks like it is just a oil weep from the valve cover/rocker box, but I will go ahead and check the torque on the connector tube and line nuts as a precaution.

 

[Matt S]

Well this post and the DDP deal convinced me to give it a try. It looks a lot easier in the pictures than in a truck! I was able to pull the tubes with my fingers and didn't need the tool or the proceedure from the TDR magazine. Now if I can put them back and it starts with no leaks I'll be happy. Anyone have tips on how to get a torque wrench on the back cylinder?

 

[driverno8]

Yea, me to too. Between this thread and the DDP deal. My injectors are out to. A lot easier I guees when the motors out. Glad I did it though. I've never seen an injector, let alone hold one. All a learning process. Oh yea, how do you get the tq wrench back there?

 

[sag2]

You will have to remove the engine hoist bracket to get it back there.