The two tubes you talking about are they fuel lines? 1/2 and 3/8 lines? Once u kink one of those hoses, even the rubber one they are junk and will cause problems later. But you can just cut the bad section replace it.

 

Danny
any advice to get upper valve cover bolts on driver side I,ve seemed to striped them out and cant get anything in there to get them out.

 

Beat a twelve point socket onto it, cut the head off, chisel them to get them spinning. Hammer a torx bit into it. Hammer a stripped bolt extractor on it. Be careful chiseling it because you could accidentally break the lower cover.

Try using the torx first.


its a real pain to get to it, you might have to raise the body just a wee bit to make room

 

A great thread. After 90k miles I'm replacing the injectors and hp lines on my LB7.

A question! The 2 fuels lines with quick disconnects at the rear of the leftside head, I've removed the clips but I'm having a hard time separating the connections, is there a special procedure. Thanks

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OK, I've done figured it out, thanks to alldatadiy.com

 

great pictures. Great post. I do this for a living and I have found that for the 5mm allen bolts on the valve covers, the Snap-On 5mm universal stubby socket works the best. really. the bit seems to fit the most squarely and has the best bite out of anything else i've tried. It is pretty spendy, like 40 bucks, but since i do maybe 5 to 10 sets of these a month, it has really helped out.

High Pressure Fuel lines.... There is an updated version of these, at about 100 bucks a line. What we do at Infinity Diesel is sandblast the injector side to clean the sealing surface, and the threads. you can to the back of it too. then you gotta clean all the media out with either solvent or water and clean and blow air a few times till there is no sand left. Then you pack the injector end with a little grease. just enough to go past the line nozzle. This will keep water out and keep the threads from corroding. after you install the lines, put silicone on the back of the injector side, this will also help seal them up. Trust me, next time you do it, you'll be thankful that those lines were taken care of.

If you don't have an injector wrench like the Kent Moore J44639, you can also stick a tall bolt in the hold down hole, don't let it into the head, or a big screwdriver, and tap it sideways with a hammer, that will shake the injector out.

When you get the injectors out, feel the injector cup to make sure it is still flush with the head. If it has pulled a little bit, you'll need to reseat and reseal it with red locktite. I suggest the gel locktite, so it doesn't run when you try putting the cup in.
I also suggest installing and torquing your injector directly after the cup, so you don't forget, but also to squish the new locktite and make the best seal down there that you can. So wait till you are ready to install the injectors before you get to working on the cups.

When you get the injectors ready, you can use a little grease at the nozzle to hold the copper washer on, also grease the big o ring to help it go in the cup easier. Clean the bottom of the cup well before putting the injector in.

That's all i can think of now. Thanks for reading.

 

sweet write up & pictorial traded off my cummins and leaning toward a durimax I found a 03 crewcab dually at a dealer clean as a hounds tooth but ad says it has bad injector they want $10K books @ $17 continplating if I want to work hard to buy cheap any thoughts here if it sounds like a deal Thanks

 

^ to the poster above I will sell you mine and you wont have to worry about the injectors
Just swapped mine yesterday! This helped a ton. And after thoroughly reading this and others I found I got the whole swap done in 8 hours!

Sent from my DROIDX using Tapatalk 2

 

WoW 8 hours sounds like an easier swap than it looked ,I just drove that one at the dealer and definatly injectors issue. has anyone here installed rebuilt injectors with no problems with them ?? Thanks

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it's also 4x4

 

I haven't had a problem with mine since the install but got genuine Bosch remans for it.

 

I thought i would never find a way to replace my own injectors, your instructions and pictures are a big help in doing this step by step.
1. before getting started do we need to worry about fuel pressure in the lines, or just disconnecting the battery sufficiant.
2. If i installed bigger injectors would that keep me from replacing them later and do they get dirty any faster or less. Would i have to change anything on computor due to bigger injectors.
Thanks
EL Bombero: