Could somebody give some advice for changing the injectors. Reading in the Haynes manual sounds like a lot of potential problems if not done perfectly.
Hello, I will go step by step on this. Step 1: REmove the valve covers. On the passenger side you need to pull back the silver heat shielding and remove the black vacuum box. It's easier to remove the valve cover and necessary to remove the injector. On the driver's side try to remove the bolt under the breather crankcase assembly with a box wrench if possible, so that you won't need to replace the o-rings under it. You can disconnect the breather elbow and put a regular hose clamp on it during reassembly. Step 2: disconnect the electrical connectors to the injectors and glow plugs and electrical connectors. Step 3: Remove the Oil Gallery Drain Plugs. There are two per head located at the top between the injectors for 1&3, 5&7, 2&4, and 6&8. About 1/2 to a quart of oil will drain out of each rail. Remove the Oil Director Spouts located on the top corner of each injector. Step4: Remove the Hold Down Clamp Bolt at the bottom of the clamp for each injector. Pull up on the bottom of the clamp and push up and over the shoulder bolt on the top of the clamp. Step5: holding the clamp up over the shoulder bolt with one hand and putting a small claw under the top of the clamp and prying up. The injector should slide out with some pressure. There is a special tool you can use for step 5 but you really don't need it . Step6: For each injector remove the copper gasket on the end. The splicing part of electrical pliers works well here. Remove all the o-rings without scratching the groove surfaces. Since they give you a new back-up (steel) ring I replaced it too, but the instruction say you don't have too. Install in the reverse order. Take care not to roll the light blue ring in the middle groove. You want the blue facing outward. Make sure all the rings are snug to the top edge of the grooves. Sometimes the little copper gasket can fall off so put a little dab of grease on the end to give it some stick and push it on with a socket. Make sure the shoulder bolt torque is 120 lb-in. Liberally lube the injector and o-rings with brake cylinder assembly lube. You can then push the injector in and engage the clamp under the shoulder bolt. If you've waited for the rings to shrink and use the lube you should be able to push it all the way in with hand pressure. If not use the special tool in the instructions or a 5/8 box wrench on the bottom of the clamp for leverage. Install the Hold Down Bolt in the bottom of the clamp and torque to 120 lb-in. Install Gallery Drain Plugs To remove the Glow Plugs you need a 10mm INTERMEDIATE socket. If you use a standard deep well you will not be able to pull it out after backing the glow plug out due to the rocker arm. After you back them out you can grab them with pliers. After removing the glow plugs set your valve covers on. You can put a bolt in to hold them if you want. People will tell you to turn the engine over BUT DON'T DO IT. This is a real caution, you can bend rods. Bump the engine using the starter solenoid. By removing the glow plugs you allow all the oil/fuel/etc in the cylinder to blow out the hole. Bump it slowly and then after a few times let it turn over a little to get most of it out. Remove your valve covers and reinsert your glow plugs. Next install the gasket and electrical connectors. Be careful with the little blue crush boots in the connectors. Sometimes it's easier to pull them out and put them on the male end to make sure you're connected right. Don't forget the glow plug leads. Install Oil Director Spouts on each injector to 105 lb.-in. Install valve covers and tighten to 97 lb-in. Your are done. Thanks Adam
