Well it's been about 6 months since I started working on my truck and finally got it finished about 30 minutes ago. I replaced all 8 injector sleeves with the heads still on the engine, in the truck. Mainly it took me so long because I just didn't kick myself in the a** and get it done. I guess I was nervous I screwed something up, because when I tapped into the sleeves toi remove them, I accidently tapped the injector bore in the head on #2 pretty bad. I finally came to the conclusion that I was pretty much F'd either way so I went ahead and smeared some JB weld down in there and sanded it smooth with emery cloth. I put new o-rings and washers on all the injectors, said a prayer and spent all day today installing them and buttoning everything back up. Sure enough it took about 10 mintues of cranking before it fired, and when it did it smoked like crazy for about 20 minutes but my truck is ALIVE! No CEL's, misses, hesitations, strange noises, etc. so I am very excited (and a little proud of myself!)
Heres a list of the few snags I ran into...
I had to undo my PITA 4in. downpipe to access the plug on the back of the head, not too big a deal though.
USE THE STEEL GUIDE when you tap the sleeves out or else you could end up like me doing the whole job on a prayer!
When installing the new sleeves be sure to wack the tool pretty hard and listen for a tone change when they bottom out. I almost did not seat #1 all the way and luckily the sealant did not set up before I realized my mistake.
I had to get creative with a 2x4, a pry bar, and a buddy to seat #4 injector all the way, even when oiled up they are pretty hard to get down all way.
BE SURE TO DRAIN THE COOLANT before pulling a sleeve out or you will be like me and dump gallons of coolant into the cylinder, etc. Befoire I fired my truck up today I drained the oil and about a gallon of coolant came out first. Now I need to go through the process of a few oil changes next week and draining the coolant again to get all the diesel out of it, too.
This was not a snag, but it took me a minute to figure the best way to get everything out of the cylinders AFTER installing the injectors. I ended up pulling all 8 glow plugs then crawling under the truck and jumping the little wire to the big wire on the starter. If you are like me and had to unhook your exhaust at the turbo, watch out because you will get soaked with coolant/oil and that was not fun.
All in all it was kind of a pain, but I saved a lot of $$ doing it myself, and if I was more motivated I could have done the whole job in a weekend.
I paid $88 for the sleeves and about $70 for the o-ring kit = fixed truck
oh yeah I bought some tools for about $300 from a guy on this site which helped out a ton, could not have done the job w/o them...