6.0 Injector swap.. - Diesel Truck Forum - TheDieselGarage.com
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post #1 of 29 (permalink) Old 12-30-2008, 04:48 AM Thread Starter
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6.0 Injector swap..

Its not for the faint of heart... there is alot invovled... tommrow when Im at work I will post up the pics of me doing it. I got as fas as taking the valve cover off, it was 4:40 and I didnt feel like working anymore..

Tools-
Fleat head screwdriver
8mm
10mm
pliers
12mm
T30 torx (04 and newer trucks)
Or 03's 8mm for the oil log
I think its an 8mm allan head.
Long T40..
swivel 12mm
extentions


Start by taking off the air filter and intake tubing, Take out the 8mm bolts that hold the degas bottle. Wiggle the bottle out. Crimp the hose that is connected to the bottle. then take off the hose clamp. QUICKLY block the hole with your finger so coolant does get out. Flip it up and lean it against the turbo.

Now that you got some room, depending on the year(s) there are diffrent brackets to hold the FICM on.. I cant remember the the 03's off my head so Ill explain the 04+ take off the two 10mm nuts on the front bracket.And the bracket that goes to the intake tube to the turbo. Theres two 8mm bolts in the back that also hold down the FICM, Un-do the FICM, and start taking off the brackets that the FICM was sitting on, theres four 10mm nuts. Take off the 10mm ay the exhaust sensor and disconnect it.

Now time for the valve covers,( remember the pattern) or you'll be scratching your head.. take off all the valve cover bolts, the back one by the fire wall you will need a swivel socket with a 3in ext.( thats a bugger sometimes) remove the valve cover and gasket.. now your looking at the oil log. With the allan head remove the front branch tube and look at the o-rings.. IF THERE CHEWED REPLACE THEM.. or you will be going back in to do them. Take the T30 and start removing all the little bolts that hold the log down. Pry up on the log, Exposing the injectors ( do it fast the log will make a mess) take a flat bladed screwdriver and push in on the metal tab on the injector where it connect to the harness and wiggle it out. Now to get the connector out of the head I use a 3/4 or 19mm shallow socket right on the connector and get a set of pliers on the plastic in the back and it comes right out..( I will post up pics) take the long T40 and unscrew the bolt and holder. ( Its slotted so it only goes in one way) Its not like the 7.3's where you have to pry up on the injector as soon as you loosen up no that torx bolt the injector comes up with it.. pull out the old injector and put the new one in. I leave the bolt and holder as on and fit it on the new injector and drop it in as a hole.. tighten it down push the connector through, connect the connector, put the log on, branch tube, T30 bolts, valve cover, FICM, intake, degas bottle..

If you have an 03 you wont have branch tubes you;ll have a steel braided line.. that you will need a U shaped tool to take off the quick disconnect ( like the HPOP lines on a 7.3) take the 8mm bolts out first it makes the disconnect easier. ( I do have a pic of the earlier logs)

To do the passanger side. Same process but you have to take off the intercooler tube.

Like I said I will get pics up tommrow to make it easier. Fill me in If I forgot something.

Jordan

95-dodge 2500 built to the hill... - sold to litle brother
03- stroker 6.0 studs and basic BS

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post #2 of 29 (permalink) Old 12-30-2008, 04:51 AM Thread Starter
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The first pic is one of a distorted o-ring on the branch tube that caused a no start when hot condition along with alot of other blown out o-rings...

and the 2nd pic is of 03 oil log...

Jordan

95-dodge 2500 built to the hill... - sold to litle brother
03- stroker 6.0 studs and basic BS


Last edited by blackcloudCTD95; 06-03-2009 at 12:42 AM.
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post #3 of 29 (permalink) Old 12-30-2008, 03:24 PM
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Just done mine a early 03. The original copper crush washers on mine were different than the new ones you get now. The original ID was on the washer was round and did not grip the injector tip. When removing the injector, 4 or 5 coppers were still in the hole. # 7 and 8 cylinders were a pain, but with use of a mirror, they come out.
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post #4 of 29 (permalink) Old 12-30-2008, 06:14 PM
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im payin to have it done! but thats a great write up jordan

Garrett






BRING BACK THE OLD TDG!
oh well, i have a map to the darkside

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post #5 of 29 (permalink) Old 12-30-2008, 09:03 PM Thread Starter
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Posting up pics.... Now. I pulled the WRONG side injector out... me and the boss didnt catch that mistake. no worrires I got the other side (passanger side) all tore down, injector out and put the log back on the drives side with the injector in, in about an hour and a half...

Jordan

95-dodge 2500 built to the hill... - sold to litle brother
03- stroker 6.0 studs and basic BS

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post #6 of 29 (permalink) Old 12-30-2008, 09:07 PM Thread Starter
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Excuse me you pull out the BACK plugs Not the front ones

Jordan

95-dodge 2500 built to the hill... - sold to litle brother
03- stroker 6.0 studs and basic BS

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post #7 of 29 (permalink) Old 12-30-2008, 09:09 PM Thread Starter
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Dang I have to make two posts in pics.......

Jordan

95-dodge 2500 built to the hill... - sold to litle brother
03- stroker 6.0 studs and basic BS


Last edited by blackcloudCTD95; 06-03-2009 at 12:42 AM.
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post #8 of 29 (permalink) Old 12-30-2008, 09:11 PM Thread Starter
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ANd more

Jordan

95-dodge 2500 built to the hill... - sold to litle brother
03- stroker 6.0 studs and basic BS


Last edited by blackcloudCTD95; 06-03-2009 at 12:42 AM.
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post #9 of 29 (permalink) Old 12-30-2008, 10:02 PM
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dang, that looks a lot different than an 03 oil rail....want me to get some more pics for ya when i swap my inj out on friday jordan?

1st murdered out 2011 F250 CC SB Fx4 lariat
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post #10 of 29 (permalink) Old 12-30-2008, 10:03 PM
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get ya a digital camera instead of your phone to take pics next time too! good writeup buddy!

1st murdered out 2011 F250 CC SB Fx4 lariat
2008 F250 CC SB 4x4 lariat dark stone, s&b intake, 5" flo pro straight pipe, 7" flo pro tip, sct livewire custom tuned by Eric @ IDP
Previous Rides:
2003 F250 CC SB 4x4 lariat centinneal black on black modded up
2001 F250 CC LB 4x4 xlt maroon lifted up
1997 F150 EC SB 4x2 xlt red
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