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DIY Injector Replacement

HoytBows

HoytBows

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Ex-Michigander, now Elizabeth Colorado
Alright guys. I need to replace some injectors. My #2 and #6 injectors are running a hight balace rate and my truck blows white smoke like a champ.

I want to do it myself. I think i can do it. I could take apart a gas motor and put one back together but I dont know a whole lot about the diesel deal. I have an LB7 and its my understanding that i have to pull the valve covers off and get down to a bear head to acces the injectors. I could use some help and advice....

Is there anything crazy tool wise that i might need that i might not have in my garage?

Is there anything that proves to be a little difficult on these motors that might give me grief?

Anything very technical that i need to remember?

I want to replace the whole bank when im in on that side... and for that matter what side are the #2 and #6 on.

Is there a GOOD MANUAL or does anybody have any GM aids they could email me?

Basically its all nuts and bolts and i am pretty confident in myself, but it would be sweet if i could talk to somebody who's done it before so they can tell me what to expect..

Lastly what kind of injectors should i put in. I dont want to do this again, is there anything thats better than the POS GM ones? Should i look at something high performance even tho i'm not planning on doing much more to my motor?

Any and all help would be great...
 
Sadly the GM injectors are the best out there...they are Bosch remans and IIRC the other injector co's (pensacola etc...)only replace the nozzles...

It's GM injectors or nothing...you can get them for just over $1600 for the complete set of 8 from GMPartsDirect after core exchange and shipping...
 
Isn't your truck still under warranty for the Injectors? I thought it was 7yr/200k? I'd go that route, TBH. $100 is a lot cheaper as a deductable.
 
Dad's 05 LLY said:
Isn't your truck still under warranty for the Injectors? I thought it was 7yr/200k? I'd go that route, TBH. $100 is a lot cheaper as a deductable.
Click to expand...

nope...his truck was put in service in Sept of 03'...it's two months out of warranty...I would ring the phones off the hook at GM customer service until someone listened though...
 
Ive also got a step by step write up im working on.

I know this thread is old and your probably done by now but yes both #2 and #6 are on the same side. The drivers side. #2 is at the front #6 is second from the firewall side.

I use the cheap pensacola injectors. What they do is clean them and replace nozzles which is what a lot of injector reman is. They do carry a one year warrenty as well. I did my uncles for him and they are working out great so far.

The injector removal tool is handy but you can do the same with a large align punch.

Injector replacement really isnt that hard if you take your time. It ususally takes most beginners a strong weekend. But its still cheaper in the end.

To those of you reading this post who have trucks that are covered. There is no deductable for this repair. Unless things have changed very recently.
 
i agree with Vinny. it will take the best part of a weekend. for removal of the injectors, i just used a small cats paw type tool, almost like a crow bar. very small, maybe 6" long, and 1/2" wide. oh, and good luck with the valve cover bolts, top and bottom, on the driver side by the fire wall.
 
shortcircut65 said:
oh, and good luck with the valve cover bolts, top and bottom, on the driver side by the fire wall.
Click to expand...

FML FML FML FML FML FML FML !!!!!!!!!!!!!!!!!!!!!!!!!!!!!:mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2::mad2:
 
especially when the heads on the bolts are already stripped out. and the mechanic blames it on the salt eating it away.... :mad2::mad2::mad2::mad2::mad2::mad2::icon_bs:
 
Ill be honest as many times as i thought i rounded on off , i was always able to stick the wrench in just a bit further and get it out.

Now the next one I do ill probably screw up and be f-ed
 
Took me 15 hours to do, taking my time and drinking, 2 nights after work and a good part of Saturday the first time I did it. The only thing I screwed up was the lower valve cover gasket, I should of tacked it to the valve cover with RTV them put it in place, but I didnt so of course it didnt seal right and leaked a quart of oil, and of course it have to be on the impossibly hard to get to drivers side. But really its not that bad of a job, a bunch of extensions, unversal joint, and a good 5mm allen head socket you can get most of them. There is a really nice injecter socket, that works X10 times better than a crows foot, i'd look into. And what work best for me to remove the injectors was to put the injector line back on a few threads and use that to pull them out, cross your fingers that your pre-cups dont follow. Use new seals and follow the torque specs you dont want an internal fuel leak.
 
My other method besides the special tool is to stick a large align punch in the bolt hole of the injector hold down being careful not to put it into the threads in the head, then pulling back on it to put the injector out using the holdown for leverage the same way the fancy tool does it.

This works when the motor is out of the truck. Not sure if it works when its in the truck for clearence issues.
 
after i was done, i had to bring a couple of sockets back to sears for replacement. somehow, some weld happened to attach itself to one side of the socket.:D weird, i know! so, i fixed it up to make it look like they were cracked, and voila! brandy new ones. thanks craftsman!!!
 
Got her done. Put 4 new ones in on the drivers side. 14hrs with some hang ups..... I ALMOST lost one of those lower valve cover bolts, the one by the fire wall. I used a ball end on it and it stripped it out. I hate ball ends HATE HATE HATE THEM. However I went old school on this thing and managed to get a vice grips on it and unbelievably it came out. I couldnt believe it, I thought I was f'ed. Snap-on makes a 5mm stubby allen socket that really stubby for getting back there by the firewall, i wasnt able to get ahold of one until the day i got it all put back together. (figures) But I would highly recommend getting one for this job. Stripping those back bolts is flirting with huge huge issues.

The other issue I had was with the 5/8ths lower fuel line over top of the Glow Plug Module as neither of my two 5/8th fuel line tools would fit. I ended up using a little pick to depress each of the four clips inside the female end to get it off but it probably added another hour to the project.

I took pictures of the four injectors i took out. Even tho two were bad i replaced them all. There was crap all over the tips. I'll try to get the pics up so somebody can explain to me what that junk was and were it came from...

Its all back together and runs great (didnt realize how bad it was) assuming I dont have an internal fuel leak... that would really piss me off.

Moral of the story is that its not that bad of a job.
 
There is always carbon buildup on the nozzles though I don't know why it's there. If reubstLlinv the same injectors were supposed to clean them with a toothbrush and a mild solvent.
 
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