Injector Install with Pictures for 12 Valve Engines
Assorted sockets and wrenches for intake horn, return line and grid heater connection.
¾” Open Ended Wrench (for injector line removal)
22 or 23mm deep well socket (can’t remember exactly what size it is)(for injector hold-down nut removal)
1 lug nut from your truck
1 small piece(less than 2”) of 3/4” pvc pipe
So you just got your sexy new injectors fresh outta the box…well heres an easily explained way to remove and install the new.
To begin this process, remove the intake horn completely from truck, once removed there are 2 wires going to the grid heater remove the nuts(10mm)holding them and tuck out of the way.
Next take a 3/4” open ended wrench, loosen and remove the entire injector lines.
Once the injector lines are removed you will then need to remove the entire fuel injector return line which runs along the base of the injectors.
Each injector has one small banjo bolt to hold the return line to the injector, simply remove this bolt, now you will see that the return line crosses the engine and goes to the filter housing, remove this banjo bolt and the entire assembly will come out, do not bend it.
Once that’s out of the way you can now remove the injector hold down nut which I think is 22 or 23 mm, I used a deepwell socket and an impact and all 6 came out very easily.
Here are the hold down nuts.
Now you are exposed to the injector body and with a little work these will pop out very easily. I have found the best and cheapest way to pop free the injectors is to get a small piece of ¾” pvc pipe about 1” long, put that over the injector and use a washer on top of that (where the hole is big enough that the threads can go through and then tighten it down with a lug nut, a few turns clockwise and the injector will pop right out. Here you will see what I am talking about…
Now the injectors should all be out and they will probably look like this
Once out, clean the injector bore, and make sure the sealing washers didn’t fall off the injector while removing them.
Once clean, install new injectors in the bore(make sure to install new sealing washers) and they should almost fall in place, do not force, make note of where return line hole is and small ball on the side of injector body, its there for a reason to line up and hold itself in the head/bore.
Place all injectors in bore properly, then reinstall and tighten injector hold down nuts.
Next take a look at the return line you took off, remove the old sealing washers and replace with the new ones.
Reinstall return line and banjo bolts to the injectors and to the filter housing, make tight and then reinstall injector lines, make tight at the DV side but on the injector side keep slightly loose(to aid in bleeding process) crank engine and once fuel spurts out stop cranking and tighten the lines, then fire it up, check for leaks and enjoy.
Also if anyone is curious, the new injectors are 5x.014 set to 280 bar, and the stock injectors pulled out had about 240,000 on the clock and they all popped off around 210 bar(stock setting is 260) so thats just for reference if anyone's curious as to how much pop is lost over the miles.