Injector Change-out

[andy666]

Just a note. There is no need to crank the engine with the injector lines loosened off to bleed the air out. Just put everything back together, pump the hand primer until it goes hard and start the engine like normal.
The high pressure fuel pump flows enough fuel that it pushes the air out off the common rail.

the hand pump only prims it to the pump it doesn't bleed the air in the lines.

When the engine cranks, the high pressure pump flows enough fuel that it pushes the air out of the rail and injector lines and returns to tank.
It was only the older rotary and in line pumps that needed the lines cracked. That's because they had no high pressure pump, only a low pressure lift pump. Even then if your lazy, they would eventually fire without cracking the lines

[StevenS]

I found the same, when replacing the injector copper washers a few months ago (essentially the same procedure you've listed) I was able to get the engine running just by pumping the hand primer even without cracking the lines. Fired within about 10 seconds of cranking

[hilder91]

U can do it either way. this is just my way.

[boxhead55]

If the suction control valve is working correctly. No fuel should get past it with the engine not cranking. You could if you like pump the hand plunger whilst cranking. This would involve using a mate. ( might cost u a beer).
The two posts before this are correct.
I have seen tho leaking suction control valves which will allow some fuel past.

[hilder91]

This what not to do. this is the bolt that holds the injectors down. for some reason it broke flush with the head right at the front near the cam gears. it took 10 minutes to get out. all I did was get a punch and struggled to unscrew it out from the head. once I got out 2mm out I got a chisel and made a groove in the bolt so I could get a flat blade screwdriver to unscrew it.

[boxhead55]

Lucky!

And if you over tighten them too much they look like this

[Hellbound]

Looks like a torque wrench is a MUST when doing this replacement

[hilder91]

Yes it is

[boxhead55]

you got that spot on!

[amitch888]

What a sexy manly hand that is

[amitch888]

I had mine fitted by a local workshop. 4,200kms later the injector clamp broke, causing the engine to miss and blow smoke out of the tappet cover beside the said injector fuel line. Decided to fix this myself $25 for the new clamp, new seals for free and I was on my way again.

It would be very easy to over tighten these without the torque wrench!

[boxhead55]

Amitch888 I have seen the injectors wedged into the bottom of the intercooler. I wish I had a pic of that. 2 broken clamps and under hi load lowing when they failed. A huge mess.

[amitch888]

Bloody happy I pulled up and towed it home and didnt just drive home then

[hilder91]

those injectors would make a nice mess especially when it breaks the fuel line and that 30,000psi gets let out

[Bellurgan Park]

What torque settings to tighten injectors to??

[boxhead55]

Which part

[boxhead55]

[Bellurgan Park]

injector holding clamp, found it, 25nm Deadly.. Thank you...

[Bellurgan Park]

Great help, thank you..
Just a wee note pointed out to me, make sure the bolt hole that holds the injector down does not have oil in it, as bolt may feel tight but will loosen..

[hilder91]

bump