In the process of doing a bunch of work to the old man and need some advice on removing the passenger side injectors. They look pretty buried under the turbo and some sort of heat shield bolted to the engine itself.

First - Do I have to remove the upper and lower air intake to get to these, or can I work around them?

Second - Any tips and tricks for the passenger side injectors would be helpful.

It takes about 45 minutes to pull the turbo as a unit. Once it's off all the pasengerside injectors are exposed.

So to answer part of my own question, I have the upper and lower intake of which gave me access to the IP and fuel lines. So now I guess the turbo is on its way out as well. What a PITA!!!!!!!

Have you considered removing the inner fender on passenger side? That seems to be the way to go based on other threads. Here some good ones.

http://dieselplace.com/forum/showthread.php?t=34248

http://dieselplace.com/forum/showthread.php?t=37971

As mitch says,remove inner fender.I just finished working on mine.Disconnect both batteries.Take the pass.battery and filter housing out,undo all bolts in the wheel-well including the one under hood holding the battery tray.There is also a 1\4 inch bolt holding the inner fender to the grill-filler.(plastic piece between grill and bumper)Best way to remove the inner fender is turn clockwise and down,not out towards you.Removing intake not nessasary.Remove clamp on exhaust downpipe,4-15 millimeter bolts holding turbo,oil supply to turbo,two 10 millimeter bolts holding oil return for turbo,vac.line.To take out the injectors you will need a deep socket(1"3\16) and a swivel or universal and extension.I have done this a couple of times and it is actually not that bad of a job.I would also reccomend checking or changing glow plug on cyl.4 and 6 as they will be easy to get at.Also the nuts holding the turbo on might be hard to get off,use a 15mil.box end wrench with thin wall and heat the nuts with torch if needed.Believe me you don't want to strip one of the nuts.

I've done LOTS of injector jobs on 6.5s, and I've never removed the turbo, lower intake manifold or the fenderwell to change them.

High pressure lines will flex easily, just don't get too horsey with them and they will be fine. The biggest PITA is the heat shield between the injectors and the turbo. Remove the two 9/32" screws and then pry it up with a pry bar. When you replace it, use the pry bar to push the two tabs on the bracket that holds it away from the turbo a bit and it won't be too bad to replace, just watch you don't pinch a return line.

I've done LOTS of injector jobs on 6.5s, and I've never removed the turbo, lower intake manifold or the fenderwell to change them.

High pressure lines will flex easily, just don't get too horsey with them and they will be fine. The biggest PITA is the heat shield between the injectors and the turbo. Remove the two 9/32" screws and then pry it up with a pry bar. When you replace it, use the pry bar to push the two tabs on the bracket that holds it away from the turbo a bit and it won't be too bad to replace, just watch you don't pinch a return line.

Not real sure how you done that Tex but i removed the turbo, made life alot easier for me. Guess i just didn't have the right tools for the job....lol
Wanna come out next week and do my 94? lol

I'd love to have a more detailed image of what you are talking about too. I'm sure I'll have that project on the table within the next 3-6 months.
TDG,
You've always been helpful and most of all helping by passing on your knowledge since you can't be everywhere and it is appreciated.
Thanks,
Mark

Honestly TDG, would you recommend a first-timer doing it that way! Keeping in mind most of us will be trying this in our home garage with limited ability to recover if something gets buggered. Thanks for all the great info.

Well, I got'em all out!!!! Thanks to all that provided feedback.

OK, now go wash up and have a beer, then its time to reverse what you've done. Don't re-use the clips from the old return lines, get new return lines that are push on only, no clips required! (Kennedy has em and probably most fuel shops)

Sure, I'll take ANOTHER beer. :drinking:

Clips will definately not be part of the install. Tore the hell out of my hands trying to get the old ones off. Finally, I just took a pair of big pliers and yanked on the return lines.