Gonna get to my injectors and ip finally!!

[gdhillon]

Okay new issue, I was screwing in my injectors today and 1,3, and 4 (iirc) they did not want to screw in all the way. By that I mean the other injectors look like there sitting lower in the bore I can tell they are sitting lower because I can't see the threads on them. I have cleaned the bores with a 12 gauge shotgun brush and wd 40, the bores were quite dirty imo. Another thing I noticed about those "finicky" injectors was that they had a little more resistance when I was screwing them in by hand so I used a ratchet and got them in. Then i torqued to 33ft'lbs. The injectors that were sitting higher were at 33 ftlbs. (I have a feeling I may have overtightened one)

I had the bright idea to swap a injector that wasn't sitting right with one that was sitting nicely...and when I went to take out one of the 'finicky' injectors I decided to try and tighten it first so i cranked the tq wrench the 35 ft lbs and did...now it made the clicking noise but I ckept trying to tighten it....I didn't get much of a turn of the injector (maybe just two flats) and then it got a lot more difficult so i hooked up my 1'' deep socket to my ratchet and used a pipe to get it loose, once I got the injector off I see that its copper washer is no longer on it, I looked in the bore with a flash light and saw a washer that looked like it had a raised rim in the middle.....this is when I clued in that I overtighthned it and possibly effed up my bore. Then I got to thinking, if the bottom of the injector was that close to the bottom of the bore to "press" the washer out of shape that means it was bottoming out which is what its supposed to do? Anyway, I don't know what to do now that washer doesn't seem like it wants to come out at all.

The humorous part of this is this time last year I was working on the oil cooler (which took a month longer than it should have) and now low and behold a year later and my trucks down for a different repair...oh well though mistakes is how we learn and better ourselves!

Ill try and upload a pic of the #1 injector one the injectors that doesn't sit 'right"

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*I used finicky to describe the injectors that werem't sitting right

 

[gandalf]

Are the problem injectors raised up by about the thickness of a copper washer? Can you give us a wag as to how far they are above the others?

When you removed the old injectors did you verify that the copper washers came out too? It's not terribly uncommon for the copper washers to separate from the injectors and want to stay down at the bottom of the hole. Check what you removed. There should be 8 old injectors and 8 old copper washers.

If a copper washer is stuck down in one of the bores you've got to figure a way to get it out. The real trick is to get it out without damaging either the seat or the threads of the bore. A decent parts store will have a set of picks which might do the job. Another possibility is to use a flat bladed screw driver. The blade has to start down past the copper washer, down through the center, before it hits the sides of the screw driver. Then you want to tap the screw driver, fairly gently, so that it takes a slight "bite" into the copper washer. While holding a little downward pressure on the screw driver, turn it. That will sometimes break the copper washer loose. But whatever you do, don't ****** up the seat of the bore or the threads.

 

[riotwarrior]

We spent some time texting back and forth and Gav says he has all 8 OLD copper washers out with the OLD injectors.

He said he cleaned and looked and did not see any other ones.

I did mention that just cause you have 8 out does not mean that there may not have been a double stack in there from before!

Gav don't turn two flats past torque reached. Once that click happens it's set. DON'T go past that unless there is a requirement to do so.

What you will likely need is an O ring pick set and carefully work at getting it hooked on the washer and pulling it up and out of the bore!

Not sure but lay out all your old injectors beside one another and make sure that they all appear to have been seated equally.

Make sure all the copper gaskets are on those old injectors.....Now you will be needing to get new washers for the injectors you have removed or will remove.

Hope that helps

 

[gdhillon]

Okay thanks for the tip with the screwdrver. Yes, I texted Al when I first noticed the injectors being '0ff' and he asked pretty much the same question as you regarding the old copper washers. They were stuck on the old injectors and when i cleaned the bores there was no copper looking washer on the seat just shiny metal. Im not sure if you can see the picture I attached but that is how much thread you can see, and with the other injectors there threads are hidden by the injector bore

That friggin thing looks pressed in there pretty hard (i wish copper was magnetic lol) hopefully I can get it out without to much fuss. Then I will pull all 8 again and lay them side by side, im sure they are the same length as the two I compared (#1 and #6) are the same length. Once I get the copper washer out I will have to do some more cleaning and hopefully loosen, Russ gave me a whole wack of spare orings,copper washers etc so im in no shortage of those Ill just have to use vaseline to make sure they stick on.

Thanks for the input!

 

[gdhillon]

Here's a stupid thought...since the injectors are torqued down to 33 and could I just put on the tees and see how it runs? (even though some of the injectors are sitting up a little high. My thoughts are is there at 33ft lbs (what Mel recomends in his DIY article) they should be fine? What can go wrong? would I lose compression therefore causing it not to start?....yes im speaking out of desperation and wanting just to get the truck done, so ya its ok to call me crazy for even thinking about halfassing the job like this lol


But I'll have to take the copper washer out of that one cylinder and replace it with a new one on the injector.

 

[TahoeTom]

Put a straightedge like a framing square across the tops and see if they really are at different heights. I did that to mine when I found a stray copper washer on the ground. They should check out really close.

 

[gdhillon]

Okay I will do that Tom, the only thing is I can physcially see some sit lower than others. But good idea hopefully im just seeing things lol

 

[Agnem]

Is it possible that some of your high injectors are partially unscrewed from the nozzle caps?

 

[gdhillon]

By nozzle caps do you mean the black part before the nozzle? they look screwed in all the way to me and they dont seem to be loose at all

 

[gdhillon]

Im still having troubles with the injectors. That copper oring doesnt want to budge at all and I have a 5 piece 'dental' pick set. Heres some pictures of the copper oring and some showing how the injectors are sitting.....i really want to just tighten all the injectors to 33ftlbs and finish this fuel injection service.....since that copper washer is sitting so tight to seat can I just screw in the injector?

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....the pool of liquid around the gp is wd40 from when I was soaking the injectors...also it seems like im missing part of the connector on that gp ?

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this is one of the injectors that doesnt sit right....some1 please tell me im paranoid and its fine the way it is lol

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this is the copper washer thats not wanting to come back out, as you can see its pressed in there pretty tightly, the rim in the middle is actually a bit higher than the rest of the washer

*i want to get my truck up and running asap but that being said I dont want to do a crappy job and have to pull everything apart again

 

[riotwarrior]

PICS NOT WORKING...get a photobucket account upload to there and use the IMG link and put those in your thread...sorry!

 

[bbjordan]

Attachments no worky.

 

[gdhillon]

damit lol, have you tried clicking the link?....that works for me

 

[Agnem]

It's probably referencing something local on your computer.

The nozzle cap is essentially the bottom of the injector.

 

[gdhillon]

the beast is alive! thanks for all the help. it runs pretty good and i feel as though it accelerates waaaay faster. It stumbles a bit at idle, we found that the #8 tee was leaking b/c of cut orings (guess my nails are sharp lol). It is still stumbling a bit at idle as the 3rd tee seems to be leaking a bit to.Hopefully some new orings fix that issue, but anyway im really happy with how it runs sounds louder now to and fires up a lot faster....which is weird to me b/c if the tee is leaking doesn't that mean airs getting in, which should cause a hard start? Overall im happy, im busy with 2nd year electrical and other pressing issues in life right now so i ended up having to get it towed to a shop for them to finish off the job but regardless its done for the most part so im happy. Thanks to everyone for helping!