torquein down #5 injector tip and thought the torque wrench clicked, come to find I sheared a little pin in the injector that locks it down when you bolt it in so it aligns with the connector tube.NOW what, no one is going to be open on sunday, the closest cummins dealer is an hour and a half away, and my buddies boss said we shouldnt be messing with my truck again and no matter what it had to be out of the shop monday morning. Im almost tempted to line it up with the connecter tube drive it home and finish it next weekend in the driveway, or better yet pull the injector apart and find a pin that fits and jam it in. Not to smart with the amount of pressure that is in these rails. Not to mention taking a chance damaging the truck. Anyone have any advice??? I hope the cummins dealer has that pin in stock....

 

you might be able to get by with what you are saying about lining it up with the delivery tube. It is a risk to take though. If you do no have it lined up properly, you risk damaging the end of the tube also. If you can find a pin to replace the one you broke, you would be much better off.

In the future, do not clamp the body of the injector in the vise for this procedure. The body of the injector can be held with a wrench. You either have to get a thin wrench from Craftsman or machine one thinner so it works

 

Yeah wish I had Known that before, we looked at it when we pulled them and said **** if we only had a real skinny wrench. But I guess ya gotta learn somehow.

 

did the pin break off flush? Or can it still be removed so you can put a new one in?

 

I have no clue I havent taken it apart, Im done for the night. But I would imagine even if it did I can find a way to get it out. I just dont have a clue if it is just to make sure things line up or if it has to be a strong pin due to the pressure inside the rail?

 

The pin just helps line it up. The injector tube does the final line up when you go thru the torque sequence. Even when seated in the injector bore, there is still some movement from side to side with the injector. At that point you install the crossover tube, torque the injector down to 44 in lbs, back the bolts off slightly, torque the crossover tube to 132 inch lbs, torque the hold down bolts to 89 in lbs, then do the final tq on the corssover tube nuts to 37 (?) ft lbs.

 

I had a couple guys want the injectors out of my 03 but I wasn't pulling them myself. I've read too many posts about how delicate those things are. Good luck...

 

actually they were easy to pull, the only difficult part is changing the tips out. Only one spot to grap unless you have a very skinny wrench, so we put it in a vice. The **** tips are torqued down pretty tight, I think they were at 90ftlbs, and with no place to grab them they just feel like something may break-then it did. I still have no clue what Im gonna do, may head over this morning and pull the injector apart and try to replace the pin myself. I just cant see putting it back with no pin, due to all the vibration I think it will spin rub on the connecter tube and eventually I will have a fuel in my oil and a blown injector...