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Power Strokes
7.3 Aftermarket
Injector Swap How-To
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[QUOTE="vanderchevy18, post: 101001, member: 569"] This is a write up of how to swap injectors. This is written with the understanding that the intercooler piping, engine harness plug, and valve covers have all been removed. Tools needed- 5/16" socket, 3" extension, ratchet, socket knuckle, prybar, needle nose pliers, allen wrench (forgot the size), and (the way I do it) vacuum pump. First pull the electrical plug. Do this by flipping the metal retainer down and (if needed) use a pair of needle nose to gently pull down the plug and push it away from the work area. [ATTACH=full]68062[/ATTACH] Next remove the oil diverted using an allen wrench. [ATTACH=full]68063[/ATTACH] Then remove the outboard 5/16 bolt from the injector retainer. Remember, lefty loosy, righty tighty! LOL You may need a knuckle for the rear cylinders. Its kinda tight. [ATTACH=full]68064[/ATTACH] After the bolt is removed push on the hold down inboard towards the engine valley. The other end of the injector hold down is key holed. The inboard bolt will slip through the injector hold down. Then gently pry the injector up. It will take a little bit of force, but be careful not to damage anything. Put something under the prybar to keep from denting the head. [ATTACH=full]68065[/ATTACH] Once the injector is out, the oil and fuel will seep into the cylinder. This is where my method differs from some. Some will pull the glowplugs once all injectors are replaced, valve covers temporarily replaced, and the engine turned over a couple times. This results in oil going into the exhaust causing oil to run from the tailpipe and lots of white smoke. Also, the fuel that seeped inside the cylinder during the change, is blown into the crankcase, resulting in the need for an oil change. My way utilizes a vacuum pump to suck out the oil and fuel prior to replacing the injector. If your wife has an old vacuum cleaner (not one she uses) or you have a shop vac, a bit of hose, and some bendy straws, you can build one. [ATTACH=full]68066[/ATTACH] Stick the straw down in the hole and suck out all the oil and fuel. You'll have to move it around to ensure you get everything from atop the piston and down in the bowl of the piston. [ATTACH=full]68067[/ATTACH] Once the cylinder is sucked out you are ready to replace the injector. Set the injector down in the hole ensuring the hold down slips over the inboard bolt. Once lined up like the original one, use a rubber mallet and very gently tap the injector down till the tone changes and the injector is fully seated. Now reinstall the outer injector hold down bolt. Torque to 15ftlbs. To ensure a good seat of the injector, hold a straight edge across all the injectors. They should all be at the same height. Now replace the electrical plug and flip the metal retainer back on the plug. Reinstall the valve cover and other pieces removed. It'll crank a while before the engine starts. You should have a battery charger handy just in case. It will un rough for the first 20 miles or so. Go flog the **** out of er and it'll clear up quicker. LOL ENJOY!! [/QUOTE]
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