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Old 11-05-2008, 08:41 AM
Matt P Matt P is online now
a truck
 

Join Date: Nov 2007
Location: West Lafayette, IN/ Lake Forest, IL.
Posts: 11,040
I just did my stage 1 injectors not to long ago, Ive had no problems with them at all it is pretty straight forward

Here are my steps for removal

1. Remove the intake all the way to the turbo and any parts bolted on the valve cover along with the crankcase breather. Remove engine cover (if you have one). Remove the small black box on the side of the heater core and undo the vaccum line that runs from it (this will make it easier to get to some of the bolts)

2. Drain the HPOP reservoir which is a rectangular piece located in front of the fuel bowl with a plug on top.

3. Remove the valve covers which for me consisted of some 10mm bolts and 1/2" bolts but some people have 13mm.

4. Once these are off disconnect the wiring that connects to the gaskets and pull the gaskets off. At the same time disconnect all the wiring from the injectors and glow plugs to the UVCH and remove the four UVCHs as well.

5. Using a 1/8" allen socket bit and an extension take out the oil galley plugs. There are two plugs on each side located in between the front two and rear two injectors and the are a goldish color and are just a small plug. When going to remove these be sure to tap the allen bit into the plug a couple times with a hammer so it is seated to prevent stripping it.

6. Once these are removed allow the oil to drain for about 30 minutes.

7. Once the oil is drained remove all the oil deflectors on the injector which are the small silver pieces held down with a 5mm allen head. Undo that allen bolt and pull all the deflectors off.

8. Then take an 8mm socket and undo all the injector retaining bolts that are located on the side of the injector where the wiring from the UVCH went into the injector.

9. Then from the opposite side of where you removed the bolt push the retaining collar forward and starting the the rear injectors first, use a prybar to pry up on the retaining collar to pop out the injectors.

10. You start with the rear becaue the engine is on an angle so any oil will flow that direction. Next up take a 10mm deep socket and remove the glow plugs.

Now you are done with the removal
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