My Stage 1 injector thread

[Matt P]

ok here it goes

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

[Matt P]

Now for the installation

1. Go ahead and first lube up all the injectors, especially around the o-rings liberally before putting them back in. Then go ahead and start putting the injectors in and use a rubber mallet to tap them in the rest of the way to be sure they are seated. Then reinstall the retaining bolts and oil deflectors, and galley plugs.

2. Then before going any further you need to purge the cylinders of any oil to prevent hydro locking. So with nothing else hooked up, hook the batteries back up and crank the engine over with the key a few times. You will see oil coming out of the glow plug holes. Do this until just a mist comes out.

3. Once this is done go ahead and reinstall the glow plugs, preferably new ones.

4. Then hook the UVCHs back up along with the valve cover gaskets and the wiring that runs to them. Also refill the HPOP. Now it is time to get the engine started. You should do it first with the valve covers off to inspect if anything is wrong. Crank for about 15 seconds each time giving it gas then let the starter rest for a minute or so. Dont get scared it took me about 25 minutes to get it going. Once you do let it run for a couple minutes.

5. Once that is done go ahead and put the valve covers and everything else back on

6. Once all that is back on go ahead and start it again and drive it for about 50 miles to get all the air out and be easy on it so you dont risk scoring the tips of the nozzles and enjoy the new injectors!

[MacDougall]

Here's a tip for getting the passenger side valve cover off. I'm not sure how others did it but that rear nut against the firewall is a pain the the azz to get. Is what i did was used a 1/4" drive ratchet with a shallow socket and went under the truck and reached up from the bottom and it was 100X easier then any thing else i tried. I'm not sure if this is what other people do as well but i found it to be the easiest way to get that nut off.

[97-Stroker]

couple of dumb questions but since im about to do mine in about a month i wanna be ready lol. When you say drain the HPOP. how do you do that? does it drain like the oil pan or do i need to suck it out of it or something. Then when you say fill it back up. you mean with new oil right? Sorry im just double checking.

Thanks man.

[MacDougall]

Originally Posted by 97-Stroker

couple of dumb questions but since im about to do mine in about a month i wanna be ready lol. When you say drain the HPOP. how do you do that? does it drain like the oil pan or do i need to suck it out of it or something. Then when you say fill it back up. you mean with new oil right? Sorry im just double checking.

Thanks man.

There is a plug on the top of it that is an allen head (dont remember the size) you take that off and you have to suck the oil out with some thing, i used a syringe thing you would give animals medicine with. And yes you just fill it back up with new oil of your choice what ever it is you use.

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Last edited by MacDougall : 10-16-2008 at 05:40 PM.

[7.3TurboDiesel]

awhile back in this thread u guys were talking about glow plugs. I know autolites are junk but have u heard anything bad about bosch glow plugs. I ordered some but they still havent arrived yet. Also props to this thread about changing injectors, i plan on doing this in the next month or so. I will go with stage ones also. But i think i will just buy mine from outlaw diesel.

[Matt P]

Originally Posted by MacDougall

There is a plug on the top of it that is an allen head (dont remember the size) you take that off and you have to suck the oil out with some thing, i used a syringe thing you would give animals medicine with. And yes you just fill it back up with new oil of your choice what ever it is you use.

yep thats exactly what I did

Originally Posted by 7.3TurboDiesel

awhile back in this thread u guys were talking about glow plugs. I know autolites are junk but have u heard anything bad about bosch glow plugs. I ordered some but they still havent arrived yet. Also props to this thread about changing injectors, i plan on doing this in the next month or so. I will go with stage ones also. But i think i will just buy mine from outlaw diesel.

Thanks man, I think bosch glow plugs would be alright

[7004]

Originally Posted by taylorking

oh yea i know for sure i wont get that kinda power outta the stock injectors. i'd guess 250 at the most.

yea his is an early '99

if nothing else he wouldnt beat me as bad, and would stop tellin everyone at the firehouse how he smoked me

i did smoke you