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Discussion Starter #1
so i got my injectors back from f1 today. i went to put the first one in and it was pretty tight. i pulled it out and gave it a good once over and everything looked fine. i have had these injectors out 2-3 times already and had no issues other than a few smashed fingers. and the last time they came out was the easiest yet. so i call rip at source and ask him for advice. i asked him if the o-ring could be bigger that what i had originally. he said that it was possible. the injector was most of the way in so we devised a plan to just snug it in with the bolts. the bolts easily threaded into the holes and i began to snug each one down until disaster. one of them snapped in half. what the heck. the bolt should be pretty easy to get out once i remove the injector. but i have never had this problem. this puppy(injector) is in there snug. i tried putting another one in without the o-ring and it doesnt just fall into the hole. i tried the injector in all the holes and it goes in each of them a different amount with the same amount of force being applied. i talked to rip again and he recommended a bore brush to clean the holes out to make sure there is no carbon buildup. i am also going to order some factory o-rings from cummins to make sure they are the correct size. and i will be getting the miller tools needed to put and pull the injectors in and out without the swearing.

has anyone else had this issue. at least the one stuck is #1. it shall remain stuck until i get the miller 9010 tool to help me pull it out.

someone please post some encouraging words of advice on how to resolve my probems

thanks
ryan
 

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Discussion Starter #2
so tried the injector with no o-ring and it went in every hole but #6. i didnt want to deal with that one yet. buy my results tell me that the large o-ring is the problem. the tools have been ordered and when cummins opens on monday, i will order the o-rings and the new bolt and hopefully get it back together.
 

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carbon buildup in the injector holes from hold down bolts backing off while running and from hot/cold cycles.
common on the 5.9
you're running at least 500 hp so guaranteed to back off.

use acetone along with the bore brush to clean out the injector holes. chase the bolt holes with bolt thread chase and acetone
blow out injector and bolt holes with compressed air after cleaning.
buy new Cummins bolts for the injectors. your old bolts are stretched and overstressed.
new copper seals.
use light coating of silicone dielectric grease lube on the O rings.

use Permatex blue on the new hold down bolts and small amount on connector tube threads.
torque to spec. let set over night and check torque

this is not a hurry through job to be done carelessly.
 

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Discussion Starter #4
Thank you for the reply. I will do all that you suggested. I do understand this is not a hurry through j
 

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Discussion Starter #5
Thank you for the reply. I will do all that you suggested. I do understand this is not a hurry through job. I've got all the torque specs sittin on the air box.
 

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i just finished an injector install and noticed that if the intake valves are fully compressed that will happen. i was fighting with one of them and thought something wrong with the o-ring or the bore but as i turned the motor over a little the injector popped in like the rest. i think with them fully compressed the injector cant go in straight. hope this helps
 
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Discussion Starter #7
ordered o-rings from cummins today. holy crap. they were just under $11 each. that seams a little crazy. i can see why don doesnt use them. anyone know why they are so high.
 

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Discussion Starter #8
the truck is alive again. got the miller tool and made install a lot easier. also changed the fuel filter, cleaned the water seperator, and changed the oil. truck is ready for the road.
 
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