installing stage 1 injectors

[ryanlewis397]

I have been working on gas motors since I was young but this being my first diesel I have a lot to learn. I am going to install a set of stage 1 injectors because several of the stock injectors are missing. It seems fairly straight forward after reading the tech file and I was also wondering if anyone had any helpful suggestions or things I might run into while replacing the injectors. I was also wondering how long it usually takes to reprime the injectors after the oil is drained out and also why the cylinders are purged before reinstalling the glow plugs (and I assume the glow pugs are removed in order to purge the cylinders). Also has anyone had any problems with the stage 1 injectors? I have a lot to learn and any help would be greatly appreciated. Thank you
Ryan Lewis

[Highbeam]

I haven't done them yet either but have been reading enough to be able to answer some of your questions.

While replacing your injectors you should also spend the couple of bucks and replace the glow plugs. Having them out also allows you to purge oil through those holes. Your 10 year old plugs are nearing the end of their service life.

Check the wiring harness under the valve covers for bare spots, breaks, or other damage.

Don't leave any of the copper washers in the holes at the very bottom of the injector bore.

The cylinders must be purged because when you remove a powerstroke injector, there are oil passages within the injector bore that will pour oil into the injector bore and then down into the cylinder. You can't avoid it and you want the oil out of the combustion chambers before cranking.

[Matt P]

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

[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!


If you have any questions on this let me know

[Highbeam]

That was great Matt. Thanks for taking the time.

What exactly are you looking for with the engine running before you put the valve covers back on? Also, will oil be pouring out of the heads without the covers installed? I recall adjusting valves on a chevy 350 with the engine running and oil going everywhere.

[Matt P]

No problem man happy to help, when you start the engine with the valve covers off your are just looking for any shorts in glow plug wires and generally anything else that seems to be wrong. Oil will not be pouring out of the heads with covers installed. The only time oil will be coming out is when you purge the cylinders through the glow plug holes which could come out at a high velocity (mine did)

Also I have a thread I had started with pics and everything too, heres the link, feel free to ask quesitons on that thread too
My Stage 1 injector thread

[Soaggydogg]

Originally Posted by PSD0389

Now for the installation

4. 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.


If you have any questions on this let me know

Why are you "giving it gas"


FYI
Refilling the HPOP makes a huge difference in how quick it will fire. If you fill it and crank it and the refill it and crank... repeat, the truck will start much faster.

[Matt P]

I gave it gas cuase it wouldnt start by just cranking it over but I gave it a half pedal when I cranked it and that got it going

[burmad69]

I think he means he gave it throttle not gas

[Matt P]

yeah my bad I gave it throttle, sorry