Attention: TDR Forum Junkies Photos are posted again on page 9. Updated 11/21/17
Thanks to rbattelle for giving me the nudge to do this photo how to, and for resizing the photos so they could be posted. The injector change is not that difficult, but there are a couple of problems that can be avoided by paying attention to what you are doing. I have tried to take too many photos so I covered everything, so if it looks like overkill, it was planned that way. Now for the disclaimers.
This is intended to assist you with an injector change to make it more visual along with the factory service manual. Please follow all directions and cautions in the factory service manual. One caution in the manual is that all injectors look the same, but are not necessarily interchangeable. Be sure you know what you are installing if not making a direct factory replacement. Also note all cautions working around high pressure fuel systems. Also note the photos and directions are taken from an 04 engine and the 04 factory service manual, and might be different from the truck you are working on. Use the appropriate adjustment specs from the proper year manual. Note that 2006 exhaust valve setting is different from 03-05.
One final note, in addition to the special tools noted, this job can not be done without a quality inch pound and foot pound torque wrench which were not shown in the photos. Although the procedure shown used all the factory supplied special tools, the job can be completed without them if need be. That being said, when the injectors are $400+ each, the investment in the tools is probably a good idea. All of the special tools can be purchased at Miller special tool, an SPX company.
The following hand tools are required.
24mm or 15/16 end wrench
19mm end wrench
24mm or 15/16 socket
10mm socket
8mm socket
Screw driver
Inch pound torque wrench (I use dial type)
Foot pound torque wrench
Some gaskets might be required, so read the entire procedure in the service manual so you know what gaskets they recommend replacing. From my experience, most of the seals can be used many times as long as they are not damaged. I would suggest you have the seals and gaskets on hand unless you can obtain them obtain them quickly. Also see if they are returnable to the dealer if you do not need them. The valve cover gasket should almost never need to be replaced if it was not leaking before you removed it.
Thanks to rbattelle for giving me the nudge to do this photo how to, and for resizing the photos so they could be posted. The injector change is not that difficult, but there are a couple of problems that can be avoided by paying attention to what you are doing. I have tried to take too many photos so I covered everything, so if it looks like overkill, it was planned that way. Now for the disclaimers.
This is intended to assist you with an injector change to make it more visual along with the factory service manual. Please follow all directions and cautions in the factory service manual. One caution in the manual is that all injectors look the same, but are not necessarily interchangeable. Be sure you know what you are installing if not making a direct factory replacement. Also note all cautions working around high pressure fuel systems. Also note the photos and directions are taken from an 04 engine and the 04 factory service manual, and might be different from the truck you are working on. Use the appropriate adjustment specs from the proper year manual. Note that 2006 exhaust valve setting is different from 03-05.
One final note, in addition to the special tools noted, this job can not be done without a quality inch pound and foot pound torque wrench which were not shown in the photos. Although the procedure shown used all the factory supplied special tools, the job can be completed without them if need be. That being said, when the injectors are $400+ each, the investment in the tools is probably a good idea. All of the special tools can be purchased at Miller special tool, an SPX company.
The following hand tools are required.
24mm or 15/16 end wrench
19mm end wrench
24mm or 15/16 socket
10mm socket
8mm socket
Screw driver
Inch pound torque wrench (I use dial type)
Foot pound torque wrench
Some gaskets might be required, so read the entire procedure in the service manual so you know what gaskets they recommend replacing. From my experience, most of the seals can be used many times as long as they are not damaged. I would suggest you have the seals and gaskets on hand unless you can obtain them obtain them quickly. Also see if they are returnable to the dealer if you do not need them. The valve cover gasket should almost never need to be replaced if it was not leaking before you removed it.
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