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Old 01-28-2012, 10:08 PM   #1 (permalink)
4thesporty
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Replaced my injectors (with pics)


Last weekend I was able to get my injectors replaced! I bought a set of 8 from ebay user "moneyslave" a few weeks ago ($275 shipped) and dropped them off at a local (kind of) injector shop to have them tested and popped to 2200 psi( $70.00). I then ordered an injector install "kit" from Kennedy diesel(~$35.00):






Got the old Mercedes and the wifes Pontiac out of the garage so the truck could fit in to get out of the wind.



This is what we are starting with:






I decided that I would do the driver's side first, them start the truck to "prime" that side before I dove into the passenger side. This was definately a good idea, as I had no trouble starting the truck at any time, and I never had to bleed anything to get it started.

I started with the first two cylinders by removing that small bolt holding the lines on (right next to the oil dipstick). Then I removed the injector line nut (19mm) and just pushed those two injector lines out of the way. There is plenty of flex in them to do this. I would not recommend bending them.




I used a Kent detroit diesel injector socket (30mm) to remove and install my injectors. I got it for around $30 on amazon. I could have bought a deep 30mm for about half that locally, but I had issues using an over the counter socket when I did injectors on my mercedes 300sd and really wished I would have bought the appropriate one them, so I layed out the cash for this:




(BTW if anyone needs to borrow it you are more than welcome as long as you lay out $35 deposit....not sure why this board doesn't have a tool loaner program......I digress.)

Here is the new injector, ready to go in. Notice the molykote on the threads. Anytime something with threads comes out of my engine, it gets this before it goes back in. Also notice that I kept the plastic cap on the injector while installing it and only removed it to install the injector line nut back on. This keeps any crap from getting in there.



The back two on the DS are pretty much the same with a little less room due to the master cylinder and brake lines.



So, like I said, once that side was done I fired it up for about a minute them killed it in preperation for the PS. Some say this can be done with the turbo left on there. For me, it seemed like it would be easier with the turbo off, so that's what I did.

The start of interference removal:



My buddy pulling the wheel to start getting out the inner fender.



Turbo is out. The only hard part of this is getting the drain line nuts off. Also, I didn't think to buy a gasket for the drain line, so in the middle of this we went to the parts store and got some high temp paper gasket and made one.



Here is the shot with the turbo removed. This access is why I wanted to remove the turbo



I can see how one would do it with the turbo on there, but it only added another hour or so to get the wheel, inner fender, and turbo out so that is what we did.

All in all this job took about 6 hours with a run to the parts store in there, and plenty of BS time.

Now, after having them in there for almost a week I can tell you that the truck does start better, meaning there is less crank time. It does run smoother while idleing. I still have a vibration somewhere, but it is much better now. The butt dyno seems to notice an increase, but it may all be in my head. I don't know if the injectors I removed factory (180,000) but they were all Bosch (made in Germany) so I will probably be having them tested, to see what condition they were in. The having them rebuilt and either put on the shelf as spares, or sell. I don't know yet.

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1994 Chevy K3500 4x4 Crew Cab SRW 212,000 miles
-SOLD 05-08-15
HX40WII Turbo
-4" Turbo Back DE Exhaust
-FTB upgrade with SS -6an line from tank to IP
-Walbro FRB-5 LP with pre and post Wix Filters
-New Bosch Injectors (2200 psi)/Duraterm GPs
-Buddy's single tow tune
-RCD 6" lift kit

Last edited by 4thesporty; 01-28-2012 at 10:11 PM. Reason: added prices
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Old 01-28-2012, 10:20 PM   #2 (permalink)
PrivatePilot
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Looks good.

Keep a close eye on the turbo oil return. When I had some work done on the road a few years ago the hack-shop that did it (in West Yellowstone WY) tried the "make a gasket" route as well. It promptly failed and I leaked a crapton of oil the entire rest of the drive home - so much that I had to check the oil at every fuel stop....

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SOLD: '97 C3500 Crew Cab Long Box Dually 6.5 Turbo Diesel.
Rebuilt with Navistar 506 block spring 2012
Special thanks to Racer55 and WhiteK2500 for their invaluable assistance!
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Old 01-28-2012, 10:27 PM   #3 (permalink)
Big Bertha
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Good job, great pics!
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Derek-
1996 K3500 Dually (f code)
-GEP motor with ARP head studs
-HX40 compressor wheel,HX35 CHRA 14cm2 with a peninsular intake
-Diamond eye exhaust
-All new accessories at 204,00
--4An fuel lines from tank to IP
-Pre and post LP filters, Walbro FRC 10
-Pillar gauges, battery mod, upgraded GP wires
-Braided oil cooler lines, PMD in bumper
-New IP
-S&B CAI,20" 9 blade fan
-223,000 miles
.
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Old 01-28-2012, 10:36 PM   #4 (permalink)
StoonTurboTahoe
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Nice work. Did it get louder after?
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1997 6.5L TD Tahoe, 4x4, LT, Z71
Heath GL4 "F" tune, HX40W-II, Custom 4"intake from K47, Custom 3"dual exhaust, F manifolds, FRC-10, FTB, Vac deleted


2009 6.6L Duramax Silverado 2500 CC SB, 4x4 LT Z71
EFI Live Tune, 4" FlowPro Duals
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Old 01-28-2012, 10:56 PM   #5 (permalink)
4thesporty
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Quote:
Originally Posted by StoonTurboTahoe View Post
Nice work. Did it get louder after?

Yea, I was going to mention that the injectors nailed for a couple of minutes when I got it started. You just have to let it idle for them to self bleed any air.

I think it is a little more "clackety" in the morning when cold.
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Adam

1994 Chevy K3500 4x4 Crew Cab SRW 212,000 miles
-SOLD 05-08-15
HX40WII Turbo
-4" Turbo Back DE Exhaust
-FTB upgrade with SS -6an line from tank to IP
-Walbro FRB-5 LP with pre and post Wix Filters
-New Bosch Injectors (2200 psi)/Duraterm GPs
-Buddy's single tow tune
-RCD 6" lift kit
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Old 01-28-2012, 11:31 PM   #6 (permalink)
StoonTurboTahoe
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Was just saying because when I did mine it got louder and I didn't know this was normal so I was a bit concerned till I did some reading.
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1997 6.5L TD Tahoe, 4x4, LT, Z71
Heath GL4 "F" tune, HX40W-II, Custom 4"intake from K47, Custom 3"dual exhaust, F manifolds, FRC-10, FTB, Vac deleted


2009 6.6L Duramax Silverado 2500 CC SB, 4x4 LT Z71
EFI Live Tune, 4" FlowPro Duals
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Old 01-28-2012, 11:37 PM   #7 (permalink)
TurboToaster
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I can't seem to find the injectors from moneyslave on ebay. What can I search for?
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2002 GMC Sierra 2500HD (Green Goblin) CC/SB 4x4, Leveled, LB7/Ally, G80, 3.73 gears, Edge Juice w/ Attitude, custom 180 amp alternator, 285/75R16 Goodyear Wrangler Silent Armors, Autometer Ultra Lite Boost/Pyro gauges, Banks Big Head WG actuator, Turbo horn mod, MBRP 4" DP back exhaust w/5" black tip, Monroe Reflex shocks, high idle, All on brights, CAT fuel filter,PPE boost valve, Pioneer deck w/6.5" Pioneer door speakers and 12" JL Audio sub *SOLD*

1993 Chevy K3500 SRW 4x4 6.5TD NV4500 5 speed, 4.10 gears, all mechanical, no vacuum pump, no A/C, timing slightly advanced, non-EGR (factory), ARP head studs, Fel-Pro HG, new casting "updated" heads, 60G GPs, solid flywheel conversion

1984 GMC High Sierra 4x4 2500, J code 6.2 diesel, 700R4 trans
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Old 01-28-2012, 11:41 PM   #8 (permalink)
radchevy
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Great pic's

How many miles on the last set?

Can you feel a big differance in power?
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2006 Chevy Crew Cab 4x4 8" box
96K, LBZ
Tires 305 55 20 Nittos

Sold
94 GMC Crew Cab 4x4 6.5 "F" 4L80E 4.10's
3"Down Pipe straight 3" exhuast
Home Made Boost controler @ 11 psi
1700 stall
1998 130GPM Water pump
247,100 and counting
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Old 01-28-2012, 11:46 PM   #9 (permalink)
crankme69
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Quote:
Originally Posted by TurboToaster View Post
I can't seem to find the injectors from moneyslave on ebay. What can I search for?
I just pulled up his profile on ebay & it shows he has nothing for sale...I think he is sold out & done with the injectors.
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1995 1500 Silverado 6.5TD 2WD Ext Cab 246K, FSD cooler bumper mount, Buddy 3 pos chip, DE 4" exhaust, K47 with F intake

1995 Tahoe 6.5TD 217K Buddy chipped cat & muff delete

1994 1500 Silverado 6.5TD 2WD RCLB 208K Buddy chip F intake, daily work commuter 21mpg avg

2005 FLHTC 107 Twin Cam Tman 625 cams, 10.1 CR, Mik 45, DTT map, 3.37 final, E1 clutch & VPC with SE 6 sp, SnS roller rockers Bub 7 2 into 1 exhaust, 120Tq & 120Hp

1995 FXD 80 EVO V Thunder 2015 cam, Mikuni 42, SE slip ons, 80Tq & 70Hp
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Old 01-29-2012, 12:37 AM   #10 (permalink)
Paveltolz
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Oil Drain Gasket.
Not sure what the GM Number is but Dodge uses the same one:
Part Number 5264569. "Gasket, Oil Drain"

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1996 Chevy K1500; 5th Owner.
Heath Stage III(ish) Performance Kit: Max-E Tork performance tune, Hurricane 7 Turbo upgrade, HT4 Cam, HO Bosch Injectors (2400psi) PMD Isolation kit, 4" exhaust w/cross over kit, Super Duty Water Pump & Fan, Heavy Duty Wrist Pin Bushings, Studded Main kit and Cold Air Intake Kit (2nd Edition). Plus ARP head studs & Air DogII DF-165 and Fluid Dampener. Lube Specialists Oil Cooler kit. PT Wiring Solutions' Zer0 Gauge Battery Cable and Glow Plug wiring kits. Walking J Feed the Beast & Rattle Stop kits.

1999 GMC Burb 6.5 K1500 HD; 2nd Owner. Heath Goodies: PMD, Water and Oil Cooling; Hurricane 7 Turbo upgrade; 2nd Gen Air Intake. PT Wiring Solutions and Painless Wiring kits too.
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