6.9 and 7.3 IDI injectors are known to be extremely robust and simple designs; however, sometimes removal of these injectors can be quite tricky. Difficult removal is generally caused by old leaking copper washers that sit under the injector in the injector bore. These washers are meant to seal combustion gasses off from the injector bore, but when they leak they will deposit carbon around the injector, making it very difficult to remove.
Step 1 Remove hardlines where they connect to the tops of the injectors and remove your return lines.
Step 2 (optional) Remove hardlines where they connect to IP for additional room
Step 3 Spray all 8 injector's bases with a penetrating lubricant and remove injectors with 1" wrench or socket
Step 4 Inspect injectors to see if the copper washer stayed on the injector body or in the bore (if in injector bore, remove with either a pick or with flat head screw driver
Step 5 Clean injector bores thoroughly, a wire brush meant for 12 gauge shotguns works perfect, you will need several. Place a dab of grease at the bottom of the bore to catch any carbon from falling into the precup or remove glow plugs and blow compressed air through the glow plug bore to remove any contaminants that are broken free. Hopefully you don't have to start with this:
To reinstall original injectors or rebuilt units, first place new copper washers at the bases of the injectors and apply a coating of antisieze compound to the injector threads and perform steps 1-3 in reverse.
*If you are using your freshly removed injectors for cores then do your injector rebuilder a favor and clean them up nicely, wire wheel and brake clean works wonders and your injector rebuilder will love you a little more.
If your injectors fail to come out:
Don't fret.
A few different things can happen, either the injector will come to the top of its threads and no longer thread out but remains stuck in the bore or the injector will come apart.
If the injector stops threading in or out but seems like the threads are stripped this is easily remedied:
Start by applying a liberal amount of penetrating lubricant to the injector threads. Next try to wiggle the injector by placing a deep well socket over it with an extension to use for leverage. Next try to pull the injector out by hand, if it still won't come out, try and use a 15/16 wrench as a lever to pull the injector out of the bore. Next use a impact to spin the injector forward and reverse in ten second intervals either until the entire injector comes loose or the top body of the injector comes loose.
If the body of the injector separates and the bottom half of the injector remains in the bore then once again do not fret! Take a spare injector or the top half of the injector that came out and grind the threads off of it like this:
Next apply some locktite to the bottom threads and screw the top half of the injector back into the part still in the bore careful not to cross thread it. Take your impact and rotate the injector clockwise but since there will be no threads pulling the injector into the bore, it should break the bottom half of your injector body free.
If these methods don't immediately work, apply a penetrating lubricant and allow it set overnight.
Tool I made to lever the injectors out of their bores:
Step 1 Remove hardlines where they connect to the tops of the injectors and remove your return lines.
You must be registered for see images attach
Step 2 (optional) Remove hardlines where they connect to IP for additional room
Step 3 Spray all 8 injector's bases with a penetrating lubricant and remove injectors with 1" wrench or socket
Step 4 Inspect injectors to see if the copper washer stayed on the injector body or in the bore (if in injector bore, remove with either a pick or with flat head screw driver
You must be registered for see images attach
Step 5 Clean injector bores thoroughly, a wire brush meant for 12 gauge shotguns works perfect, you will need several. Place a dab of grease at the bottom of the bore to catch any carbon from falling into the precup or remove glow plugs and blow compressed air through the glow plug bore to remove any contaminants that are broken free. Hopefully you don't have to start with this:
You must be registered for see images attach
To reinstall original injectors or rebuilt units, first place new copper washers at the bases of the injectors and apply a coating of antisieze compound to the injector threads and perform steps 1-3 in reverse.
*If you are using your freshly removed injectors for cores then do your injector rebuilder a favor and clean them up nicely, wire wheel and brake clean works wonders and your injector rebuilder will love you a little more.
If your injectors fail to come out:
Don't fret.
A few different things can happen, either the injector will come to the top of its threads and no longer thread out but remains stuck in the bore or the injector will come apart.
If the injector stops threading in or out but seems like the threads are stripped this is easily remedied:
Start by applying a liberal amount of penetrating lubricant to the injector threads. Next try to wiggle the injector by placing a deep well socket over it with an extension to use for leverage. Next try to pull the injector out by hand, if it still won't come out, try and use a 15/16 wrench as a lever to pull the injector out of the bore. Next use a impact to spin the injector forward and reverse in ten second intervals either until the entire injector comes loose or the top body of the injector comes loose.
If the body of the injector separates and the bottom half of the injector remains in the bore then once again do not fret! Take a spare injector or the top half of the injector that came out and grind the threads off of it like this:
You must be registered for see images attach
Next apply some locktite to the bottom threads and screw the top half of the injector back into the part still in the bore careful not to cross thread it. Take your impact and rotate the injector clockwise but since there will be no threads pulling the injector into the bore, it should break the bottom half of your injector body free.
If these methods don't immediately work, apply a penetrating lubricant and allow it set overnight.
Tool I made to lever the injectors out of their bores:
You must be registered for see images attach
