I need some tech advice on removing the injectors from a 6.7L QSB. I don't have any special tools and am not in a place to get any. Can anyone give me any help on getting this done with basic hand tools and some inginuity?

 

I believe the QSB uses the same commonrail setup as the 3rd gen Dodges.

 

Yes it is a common rail system. I can't get the injectors out of the cups and don't want to damage them. I had a Caterpillar sleeve service tool that I sent home already that I might have been able to make work, but it's on a boat somewhere so that option is out the window.
I'm a Power Stroke driver, but the military uses a lot of Cummins and I've been to school on the Cummins but only on the NT855 with a pressure/time system 'cause that's what Deere used in the 8960 & 8970 at the time. Cummins and Dodge dealers are few and far between in Afghanistan (non-existant is more like it) so that is why I put the topic out there on DTR. Any help would be greatly appreciated.

 

You did pull the fuel feeder tube out of the head first right?

 

FUEL INJECTOR ID CORRECTION CODES:

Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool.
NOTE: Do not install new fuel injectors unless the alphanumeric codes have been recorded.

 

REMOVAL
FUEL INJECTOR ID CORRECTION CODES:
Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM.

The valve cover and valve cover gasket will need to be removed in order to manually record the values from the original injectors. Contact cleaner or brake cleaner may be used to clean the fuel injector.


NOTE: If the fuel injectors are being removed such as for engine teardown or diagnostic purposes, be sure to mark each injector with its corresponding cylinder number. The fuel injectors MUST be reinstalled into the original (same) cylinder due to the fuel injector correction code.


NOTE: Do not install new fuel injectors unless the alphanumeric codes have been recorded.



CAUTION: Refer to Cleaning Fuel System Parts.





Six individual, solenoid actuated high-pressure fuel injectors (7) are used. The injectors are vertically mounted into a bored hole in the top of the cylinder head. This bored hole is located between the intake/exhaust valves. High-pressure connectors, mounted into the side of the cylinder head, connect each fuel injector to each high-pressure fuel line.

1. Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables.
2. Remove vanity cover.
3. Remove breather assembly and tubes.
4. Remove valve cover. Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL.







5. Remove all 12 fuel injector wire harness nuts (1) securing integrated wiring harness to all 6 fuel injectors.







6. An integrated fuel injector wire harness / valve cover gasket (2) is used. After all 12 nuts (1) have been removed, remove this integrated gasket. Before removing gasket, disconnect engine wiring harness at both electrical connectors (3).
7. Remove necessary high pressure fuel line connecting the necessary fuel injector rail to high pressure connector. Refer to Fuel Line Removal for procedures.







8. A connector retainer (nut) is used on each connector tube (12). Remove this nut(s) by unthreading from cylinder head. These nuts (12) hold the fuel injector retainers (13) to the fuel injector.










9. Using special high-pressure connector removal tool #9015 (4) remove necessary high-pressure connector(s) from cylinder head. Tool #9015 threads onto connector tube. Use tool to pry connector tube(s) from cylinder head.







10. Remove 2 fuel injector hold-down clamp bolts (1) at each injector being removed.
11. Remove necessary exhaust rocker arm assembly(s).



12. USING TOOL #9010:




a. Special Tool #9010 is equipped with 2 clamshell clamps, a sliding retainer sleeve to retain the clamshell clamps, a 2-piece mounting stud, and a pivoting handle. Do not attempt to remove the fuel injector with any other device. Damage to injector will occur.
b. The rocker housing is bolted to the top of cylinder head. The mounting stud from tool #9010 was meant to temporarily replace a rocker housing mounting bolt. Remove the necessary rocker housing mounting bolt. These mounting bolts are located at the center of each of the 5 rocker housing support bridges.
c. Install and tighten 2-piece mounting stud to rocker housing. If removing the No. 6 fuel injector, separate the 2-piece mounting stud. Install lower half of mounting stud to center of rocker housing bridge. Install upper half of mounting stud to lower half.
d. Position tool handle to mounting stud and install handle nut. Leave handle nut loose to allow a pivoting action.
e. Position lower part of clamshell halves to sides of fuel injector (wider shoulder to bottom). The upper part of clamshell halves should also be positioned into machined shoulder on the handles pivoting head.
f. Slide the retainer sleeve over pivoting handle head to lock clamshell halves together.
g. Be sure handle pivot nut is loose.
h. Depress handle downward to remove fuel injector straight up from cylinder head bore.





13. Remove and discard injector sealing washer (2). This washer (2) should be located on tip of injector, or may have remained in the injector bore.







14. Measure sealing gasket (washer) (1).

NOTE: If the fuel injectors are being removed such as for engine teardown or diagnostic purposes, be sure to mark each injector with its corresponding cylinder number. The fuel injectors MUST be reinstalled into the original (same) cylinder due to the fuel injector correction code.


NOTE: Do not install new fuel injectors unless the alphanumeric codes have been recorded.

INSTALLATION
1. Inspect fuel injector :
a. Look for burrs on injector inlet.
b. Check nozzle holes for hole erosion or plugging.
c. Inspect end of nozzle for burrs or rough machine marks.
d. Look for cracks at nozzle end.
e. If any of these conditions occur, replace injector.
2. Record six-digit alphanumeric correction code located on the side of injector.
3. Inspect high-pressure fuel injector connector for :
a. Damaged tip.
b. Loose of missing alignment pin.
c. Cut or missing O-ring.
4. Thoroughly clean fuel injector cylinder head bore. Blow out bore hole with compressed air.







5. The bottom of fuel injector is sealed to cylinder head bore with a copper sealing washer (shim) (1) of a certain thickness. A new shim (1) with correct thickness must always be re-installed after removing injector. Measure thickness of injector shim (1). Shim Thickness: 1.5 mm (.060”)
6. Install new shim (1) (washer) to bottom of injector. Apply light coating of clean engine oil to washer. This will keep washer in place during installation.
7. Install new O-ring to fuel injector. Apply small amount of clean engine oil to O-ring and injector bore.







8. Install injector into cylinder head with male (high-pressure) connector port facing the intake manifold. Push down on fuel injector mounting flange to engage O-ring and seat injector.
9. Tightening Sequence:
a. Install fuel injector holdown clamp (mounting flange) bolts. Be sure the clamp is perpendicular to the injector body. Do a preliminary tightening of these bolts to 5 N·m (44 in. lbs.) torque. This preliminary tightening insures the fuel injector is seated and centered.
b. After tightening, relieve bolt torque, but leave both bolts threaded in place.
c. Install high-pressure connector (13) and retaining nut (12). Do a preliminary tightening of nut (12) to 15 N·m (11 ft. lbs.) torque.
d. Alternately tighten injector holdown bolts to 8 N·m (71 in. lbs.) torque.
e. Do a final tightening of the high-pressure connector and retaining nut (12). Tighten to 50 N·m (37 ft. lbs.) torque.
10. Install integrated gasket
11. Connect injector solenoid wires and nuts to top of injectors. Tighten connector nuts to 1.25 N·m (11 in. lbs.) torque. Be very careful not to overtighten these nuts as damage to fuel injector will occur.
12. Install exhaust rocker arm assembly. Refer to the Diesel Engine section.
13. Set exhaust valve lash. Refer to the Diesel Engine section.
14. Install fuel connector tube nut at cylinder head and tighten to 50 N·m (37 ft. lbs.). Be sure to use a secondary back-up wrench on the connector nut (fitting) while torquing fuel line fitting. Refer to Fuel Line Installation for additional information.
15. Install valve cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
16. Install breather assembly.
FUEL INJECTOR ID CORRECTION CODES:



Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM.


17. Connect negative battery cables to both batteries.
18. Programming Fuel Injector Correction Code:

Turn ignition switch “ON”.
Using a diagnostic scan tool, select ECU View> PCM > MISCELLANEOUS FUNCTIONS.
Select Injector Quantity Adjustments and click Start.
Choose appropriate cylinder number and click next.
Click on Show Keyboard. NOTE: A fault code will be set if incorrect serialization codes have been inputted.
Input six-digit Injector Correction Code and click enter.
Review code as it was typed, then click Next if correct, or edit if necessary.
Repeat the preceding steps for other cylinders if necessary.
Once all fuel injector correction codes are entered, cycle the ignition to complete.

Hope this helps
Good Luck

 

BigIron70,
Thanks for the post. I was unable to get them out before the vehicle got hauled off to be rebuilt, but thanks to your post I now know what step I was missing. I didn't know about the tubes needing to be removed and that was preventing the injectors from coming out, but now I know. I'm a Deere tech in the civilian world and none of our engines use the tube so it never occured to me. Thanks for the info

 

Greentractors,
Thank you for your service and everyone in uniform over in Afghanistan and Iraq. God Bless You!

 

Big Iron70,
Thank you for your support.