Mike S

Can anyone please tell me where I can get instructions on how to change out my stock injectors. Thanks, Mike

PourinDiesel

Ask and you shall recieve......


Injector swaps are pretty easy in 03's.

Here are some directions:

1.Remove plastic vanity cover
2.Remove hoses from breather bottle on top of valve cover.
3.Remove Valve Cover, Remove intake arm and grid heater.
4.Remove wire harness connections from rail and combo sensors, also remove injector harness connections (3 on the side of rocker box)
5.Loosen and remove all injector wires from each injector.
6.Remove rocker box (mid piece between vc and head).
7.Completely loosen all injector lines at the head, next remove bleed off banjo from top of rail
8.Remove rail feed line from CP3 fuel pump.
9.Next remove securing bolts for common rail and securing bolts for fuel lines, this will allow you to remove the common rail with all fuel lines attached.
10.Remove all male connector securing nuts and pull male connectors out enough to allow injector removal.
11.Number each Exhaust rocker, remove each exhaust rocker (sometimes it maybe necessary to bar over or remove intake rocker to swap an injector), do not loosen adjustment nut.
12.Remove all injector securing bolts.
13.Next pull out injectors.

Torque specs:
Injector securing bolt: 8mm 10nm
Injector wire nut: 8mm 1.25nm (thats extremely light) Be very careful here, if you break off the copper stud on the injector, you'll be having a very bad day!)
Rocker: 10mm 36 +/- 2nm
Male connector nut 24mm 50nm
Fuel lines: 19mm 29-31nm
Intake arm 10mm 24nm
Rocker box bolts 10mm 24nm
Valve cover and vanity cover bolts 10mm 24nm
Fuel line and rail securing bolts 10mm 24nm
Remember the Yellow and Brown wire nuts always will be closest to the intake side or rocker.

Be careful to isolate fuel system components to keep debris out of system.

PThree

Note to self: Worth every penny to pay someone to f-it up instead of being liable yourself.

TON4FUN

Seems easy to me.