Well every project I take on appears to give me headaches...I'm beyond stressed  .  I cannot get any of my injectors to budge (I've tried 1,2,3,4).  I can rotate them in their slots but they will not lift up.  All my strength and they will not move up a millimeter.  I also cannot get my number five fuel line to disconnect from the crossover tube.  I'll add pictures later but some of the nuts on the fuel lines are corroded which I suspect the issue to be with that (weird because it was California truck for 17 years).  The corrosion spread to the threads on some of the fuel tubes but I'm replacing them anyway.  

 

My only other option would be to just button everything back up temporarily.  But I really don't feel comfortable reusing these feed tubes...worried it's just going to leak like hell.  They aren't damaged/scuffed or anything but the corrosion worries me.   I may just have to tow it to my mechanic and have him try to do it because I'm getting too stressed out and I'm low on ideas.  Things shouldn't be this hard but that's the way it is. I'm trying not to go crazy...pray for me 

Edited February 18, 20178 yr by sooxies

Did you use the valve cover hold down bolts to thread into the injector and pop it up?

1 hour ago, Me78569 said:

Did you use the valve cover hold down bolts to thread into the injector and pop it up?

Yes that was my method.  Will not move at all

Are you using something to pry up with? Not recommended.

 

I cut a piece of heavy pvc pipe or pvc straight coupling cut to the right length and fits over the injector with a big washer on top you tighten the nut down and it should lift right out. Some oil soaked around ea one can't hurt for awhile before you try is good.

My injectors had around 425- 450 k miles and they came out nicely. At first I tried pulling to no avail. but the pipe and washer worked real well.

Are you just trying to pull them with your hands? I did pry mine but it took so little effort it did not bother me. Did that both times I have changed mine. I used a piece of copper pipe. I do like @JAG1's idea though especially if it is stuck. Now much different is it to remove a 12V's injectors vs a 24V?

 

I also used one of the short air horn bolts. Puts the head of the bolt about the same level as the rocker arms.

Edited February 18, 20178 yr by dripley

Do you have the crossover tubes removed?

19 minutes ago, Hawkez said:

Do you have the crossover tubes removed?

That was my first thought until I read he could spin them around. I assumed he meant 360*.

 

There is one more puzzling thing to me. That is the #5 line being stuck on the crossover tube since they dont physically attach to each other.

10 hours ago, dripley said:

There is one more puzzling thing to me. That is the #5 line being stuck on the crossover tube since they dont physically attach to each other.

 

I apologize...it will not unthread from the head.  Can only assume corrosion of some sort set in after seeing what some of the other lines were like.  I ended buttoning everything back up and nothing is leaking so I did something right.  Back to the drawing board.

Edited February 19, 20178 yr by sooxies

I take it you did have the other crossover tubes removed while trying to remove the injectors. 

http://www.torkteknology.com/cummins-injector-puller-kit-1998-5-2002-pn-cip040/

I always just use a grid heater bolt (smaller or the 2) and screw it in and pry up with a screwdriver against the rocker arms.Yes the crossover tube must be pull out a fair amount at least 1 inch to be safe.

I had the crossover tubes out 

24 minutes ago, Mopar1973Man said:

I always just use a grid heater bolt (smaller or the 2) and screw it in and pry up with a screwdriver against the rocker arms.Yes the crossover tube must be pull out a fair amount at least 1 inch to be safe.

Tried it...no luck....wiggling it as well when I was prying up.  

The only thing that is holding that injector in is the o-ring on top. The only thing I can say is more leverage it will pry out. The nozzle and copper shim will not hold the injector in. The cross over tube might if it not pull out enough. 

If tubes are out and nothing else is abstracting it, then eat some wheaties and use one of these. 

http://m.harborfreight.com/Heavy-Duty-Slide-Hammer-and-Puller-Set-16-Pc-63268.html

Not promoting china, if you have extra money by US made

It will do first 4 at least.

Edited February 19, 20178 yr by Dieselfuture

2 hours ago, Mopar1973Man said:

The only thing that is holding that injector in is the o-ring on top. The only thing I can say is more leverage it will pry out. The nozzle and copper shim will not hold the injector in. The cross over tube might if it not pull out enough. 

Mike I did some reading on it and said that if injectors have been in for a long time they can rust a bit making them hard to get out. Said to use the pipe trick w/ washer and lug nut, you told me too, or buy a puller which is basically same thing. Also to let oil soak around them too.

 

Eric said they want old ones back but not scratched or beat up to get credit for them they want them to look clean and pulled out proper way. A lug nut has the tapered tip so it keeps the washer centered when tightening and pulling out.. that way washer won't score up the injector threads on top when pulled up.

 

Edited February 19, 20178 yr by JAG1

49 minutes ago, JAG1 said:

Mike I did some reading on it and said that if injectors have been in for a long time they can rust a bit making them hard to get out.

 

 

That's on a 12V where the injector is exposed to the elements. Different story when the 24V has the injector buried in engine oil and diesel fuel.

I have been sitting here trying to figure that out. Thought maybe he was thinking about 12v. 

 

Cant figure out what would hold a 24v injector from coming out other than the crossover tubes.

What about above the O ring? And then why is Sooxies having a problem?

It could be the o-ring is burnt to the head and stuck. Again just need to pry harder. That injector is harden steel you not going to hurt the injector.

4 hours ago, Mopar1973Man said:

The only thing that is holding that injector in is the o-ring on top. The only thing I can say is more leverage it will pry out. The nozzle and copper shim will not hold the injector in. The cross over tube might if it not pull out enough. 

This is probably not my issue...but I've read about if the copper washers double up because of people forgetting.  Maybe they were replaced at some point.  What would be the effects of that situation? I've always wondered that.  

 

16 minutes ago, JAG1 said:

What about above the O ring? And then why is Sooxies having a problem?

I'm a magnet for problems   I'm still dumbfounded how I couldn't get any of them to move upwards at all.  Suction of some sort keeping them in?  I could rotate them as I said but they would not go up.           

Edited February 19, 20178 yr by sooxies

10 minutes ago, sooxies said:

This may not be my issue...but I've read about if the copper washers double up because of people forgetting.  Maybe they were replaced at some point.  What would be the effects of that situation?

 

 

 

Most likely would never get the injector in or lined up being it would stand up so much taller and the crossover tube won't line up right and spray pattern would be most likely wrong. I know there is a wide range of copper shims but I really doubt you could get 2 stacked and get a injector lined up in the hole. 

 

10 minutes ago, sooxies said:

I could rotate them as I said but they would not go up.

 

Anyways the copper shim crush to the injector not the head. So the injector will still lift out. The o-ring is the only thing that would hang it up. So if the o-ring burnt to the head is will stick and hang up. All I've ever done is screw that short intake bolt in the head and then using that flat blade screwdriver and pry them out.  I've even use small nail bars before. 

 

Edited February 19, 20178 yr by Mopar1973Man