who has experience with injector install

[lmills]

Just curious if anyone has any injector install experience with these new common rail set ups. I did the install on my old 24 valve motor and was wondering if it was just as easy. Do we happen to have a PDF file floating around yet for the injector install?

 

[Bob Wagner]

caution

the injector swap on an 03 is not as eay as the 2nd gen trucks.



I will leave at that beacause I only have second hand information

 

[MUDDY]

not as easy,,,,,but not too bad. bout a 2 hr job

 

[nickleinonen]

i remember reading somewhere that the rocker arms need to be removed to get at the injector??? true or not, i don't know. .

 

[jwilliams3]

Ask and you shall recieve... ...





Injector swaps are pretty easy in 03's.



Here are some directions:



1. Remove plastic vanity cover

2. Remove hoses from breather bottle on top of valve cover.

3. Remove Valve Cover, Remove intake arm and grid heater.

4. Remove wire harness connections from rail and combo sensors, also remove injector harness connections (3 on the side of rocker box)

5. Loosen and remove all injector wires from each injector.

6. Remove rocker box (mid piece between vc and head).

7. Completely loosen all injector lines at the head, next remove bleed off banjo from top of rail

8. Remove rail feed line from CP3 fuel pump.

9. Next remove securing bolts for common rail and securing bolts for fuel lines, this will allow you to remove the common rail with all fuel lines attached.

10. Remove all male connector securing nuts and pull male connectors out enough to allow injector removal.

11. Number each Exhaust rocker, remove each exhaust rocker (sometimes it maybe necessary to bar over or remove intake rocker to swap an injector), do not loosen adjustment nut.

12. Remove all injector securing bolts.

13. Next pull out injectors.



Torque specs:

Injector securing bolt: 8mm 10nm

Injector wire nut: 8mm 1. 25nm (thats extremely light) Be very careful here, if you break off the copper stud on the injector, you'll be having a very bad day!)

Rocker: 10mm 36 +/- 2nm

Male connector nut 24mm 50nm

Fuel lines: 19mm 29-31nm

Intake arm 10mm 24nm

Rocker box bolts 10mm 24nm

Valve cover and vanity cover bolts 10mm 24nm

Fuel line and rail securing bolts 10mm 24nm

Remember the Yellow and Brown wire nuts always will be closest to the intake side or rocker.



Be careful to isolate fuel system components to keep debris out of system.

 

[Vaughn MacKenzie]

BE SAFE!

Just a few words of caution



Since the HPCR system is under constant extrememly high pressure, an equal amount of extra care needs to be taken to ensure all fuel fittings are reinstalled and torqued to exact specs. Not only that but as jwilliams said it's critical to keep all components absolutely clean and free from any sort of damage. You don't want to be flexing lines, dinging threads, all that's a big No-No.



Evan Beck recently went to school on the HPCR system and we had a discussion on injector changeouts on these trucks. There have already been 3-4 techs die from injection system leaks working on HPCR Cummins. Remember you are dealing with a system that's under extreme pressure 100% of the time instead of very short pulses on the previous trucks. Any imperfection with the fittings could result in a leak and consequent stream of fuel under high pressure which will kill you in less than 5 minutes if it hits you.



I highly recommend that once an injector swapout is complete and you are ready for the initial fireup, SHUT THE HOOD and stand clear. Don't be poking your head or any body parts around there when cranking or starting the engine. Once you get it started, let it run a couple minutes, then shut it down before you pop the hood and inspect for leaks.



But have fun, BOMB, and be safe!



Vaughn

 

[lmills]

Oh I am well aware of the constant pressure. That's part of the reason why I asked about the install process.

 

[DIESELMAN]

While doing our safety analysis reports, I've not yet come across an HPCR related fatality, but, check this out for an example of what can happen if you screw around with that which you don't understand the dangers of... ... ... .



http://www.fluidpowersafety.com/fpsi_adv027.html

 

[Vaughn MacKenzie]

Nice link Dieselman. That guys hand looks nice



At least with hydraulic oil it won't circulate through your system as fast as diesel. If someone got diesel injected into a limb the only thing that might give them a chance is to put a tourniquet on it ASAP to cut off the circulation.



I can't tell you about the statistics, it's just what I heard but hopefully it's not true. I just want to make sure we don't see any of our TDR members get hurt although I know most of you guys know how dangerous diesel injection systems can be



Vaughn

 

[krabman]

There are a few other things to think about besides the safety issues and the difficulty of the install. One thing is that there are a lot of expensive and easy to break parts that you will be working around. Your tolerance for fiscal pain will have to be considered because several people that I know of in my area have had injector installs go south. Not people I heard of through the grapevine but people I know, I myself am one of them. Once things do go south not only is there the monetary issue to think about but further as in the case of my truck, NOBODY could figure out what was wrong. Not DC, not anyone. Between all the new computer stuff and the unfamiliarity that comes with it you may find a solution is not redily available. Fortunately I took my truck to a reputable installer and after many weeks the problem was solved and I was not out what could have been a four figure bill just in labor charges. Now Im not saying dont do it yourself but I do think if you are contemplating it you should be aware of the potential pitfalls if things dont go right.

 

[Swayse]

I've done three injector installs, all went very smooth. It took me about 5 to 6 hours to do the install.

 

[Evan A. Beck]

BE CAREFUL

Read my post here.



IMHO, unless you are qualified to work on it, leave it alone. Take your truck to a shop where a trained diesel tech can do the job right.



Chances are you won't have problems if you do it yourself, but is it worth the risk? Please think about it.

 

[Evan A. Beck]

Originally posted by Vaughn MacKenzie

If someone got diesel injected into a limb the only thing that might give them a chance is to put a tourniquet on it ASAP to cut off the circulation.

While in the Bosch class, we learned a lot about the high pressures and what can happen. Bottom line is this: Best case scenario = amputation. Quantity and location of the injury are also very important.



Subcutaneous injection is serious stuff, guys. Look it up on the 'net and read about it. It may scare you.

 

[jwilliams3]

Evan,

Pressure in the high pressure system bleeds off of the system in about 5 seconds after the engine has been shut off.

So if the person changing the injectors waits for a bit (I suggest several minutes) before opening the hood and performing the task, there should be no danger.

After the work is done, the hood should be shut and then start up can take place.



Do not break lines open to help bleed air from the lines.



Best thing to do is use common sense.



My opinions... ... .



--Justin

 

[krabman]

Evan, Lenny told me you had a hand in helping get my truck going. Thanks man, Beer's on me when we meet. Now if I could just get home so I can drive it.

 

[Evan A. Beck]

Yeah, once we learned how to troubleshoot these engines, yours became clear. Man, it hals a$$ now!!! One nice ride, thats for sure.



I'll look forward to meeting up with ya! When will you be returning?

 

[krabman]

I should be back down south around the 25th. Lenny wouldnt tell me what it dynoed at cause he wanted to suprise me. I briefly considered death threats but what the heck it is kinda fun looking forward to putting it on the rollers later this month.

 

[Evan A. Beck]

Sounds great! I'll look forward to meeting up with ya.