Stuck #4 fuel injector

03black · **Posted:** Sat May 22, 2021 9:44 pm

Are you sure that you torqued the "crow" foot hold down on the body of the injector?
Is the little steel round plug still there at the base where the foot presses down on.

If your using a new copper crush washer, maybe a little spray of copper sealant on the copper washer might help. Spray it on both side and let it set up, carefully put it on the injector tip and slid it up to the base. Then install the injector and put the foot on and torque it down.

As mentioned, use a quality copper crush washer from Mopar or IDparts. The washer is what seals the bore.

Tree Catcher · **Posted:** Sun May 23, 2021 9:42 am

WWDiesel wrote:

Get a set of fuel injector seat reamers and clean everything up.
Available on Amazon and eBay for cheap.

Will this be able to clean up the bore on the #4 injector with it still in the engine with everything still there? what keeps it square to the bottom of the bore? Id hate to get this only to make the problem worse.

rankom · **Posted:** Sun May 23, 2021 12:12 pm

when I did this on my engine, I pulled out the injectors and purchased this tool. I used 17x19 reemer provided in the kit and I used 19mm socket and ratchet and gave it about half a dozen turns. and sprayed some brake cleaner in the bore and then I installed injector with a new copper washer and tightened the injector hold down bolt. (do not over tighten).

rankom · **Posted:** Sun May 23, 2021 7:09 pm

in addition to my previous reply. I remember when I did this procedure using this tool, I lubed it with motor oil. and the tool felt like it was jamming up cutting through aluminum but I continued to turn it clockwise only until it hits the bottom of the cup. and then once it was free to turn I cleaned it with brake cleaner and removed some aluminum shavings off the tool and gave it another few turns, the bottom of the injector bore was clean, shiny and flat, so I knew it would seal this time.

krb · **Posted:** Tue Jun 22, 2021 5:41 am

Any updates on your situation?

Tree Catcher · **Posted:** Wed Jun 23, 2021 12:31 pm

I took it to a shop, loaned them the tools and now will be taking it to another shop. I sold my house and cant work on it where I am staying. Still have a leak somewhere. At first it was a loud phish phish,phish, so I tightened up the #2 injector and that cleaned it up somewhat. Now its a dull thud thud thud but only when I step on the throttle. Hoping that the parts that i ordered from ID Parts get here today, they were ordered on Friday with two day shipping.

krb · **Posted:** Thu Jun 24, 2021 6:20 am

Tough time to be dealing with this. Hope your situation improves soon.

Do you see another area of sootyness or try the tube "stethoscope" to isolate the sound?

Do you think you cracked the injector trying to break it loose?

Tree Catcher · **Posted:** Fri Jun 25, 2021 12:53 pm

I dont think its a cracked fuel injector, the last tech did replace the #1 injector. No idea on why its making a dull thud when I get on the throttle. The shop just called me and they want to take off the valve cover. They think it is a three hour job. I am going to pick it up. Ohh where in the world is Geordi?

rankom · **Posted:** Fri Jun 25, 2021 8:49 pm

Tree Catcher wrote:

I dont think its a cracked fuel injector, the last tech did replace the #1 injector. No idea on why its making a dull thud when I get on the throttle. The shop just called me and they want to take off the valve cover. They think it is a three hour job. I am going to pick it up. Ohh where in the world is Geordi?

did the shop strip the threads for the injector hold down bolt, so that's why they want to remove the valve cover to install the heli coil?

Tree Catcher · **Posted:** Fri Jun 25, 2021 11:44 pm

I will check to see if the threads are stripped. If they are and need a helicoil, i know how to do that. It just infuriates me that I can't find a half booty mechanic, let alone a decent mechanic. When I pulled into my campsite, I had a neighbor ask if i had a leaky spark plug, it was that loud. So I have ANOTHER set of brand new crush washers and O-rings to try tomorrow. If I do need helicoil set, there is a machine shop a few miles down the road that Im sure I could borrow a drill, tap and a helicoil along with a punch to get the helicoil tang out with. I wish I would have had more time at my house to figure this out before it sold. I was expecting it to be on the market for a few months, it sold in 4 days.

Ohh torque the injector hold down bolts to 28 lbs, but i read on another thread that he went 50 lbs??? Guess that will crush the washer

WWDiesel · **Posted:** Sun Jun 27, 2021 12:52 pm

Tree Catcher wrote:

Ohh torque the injector hold down bolts to 28 lbs, but i read on another thread that he went 50 lbs??? Guess that will crush the washer

2005 FSM lists: 32.4 Nm which = 23.8 Ft. Lb.s

Section 14, Page 85 wrote:

NOTE: Apply antiseize compound to injector body.
(1) Install fuel injector in cylinder head with new
seal and O-ring.
(2) Install fuel injector retainer and bolt (Fig. 16).
Torque bolt to 32.4 N·m.

2006 FSM Lists the same torque specfication.
2. Install fuel injector retainer and bolt. Torque bolt to 32.4 N·m (24 ft. lbs.).

Tree Catcher · **Posted:** Sun Jun 27, 2021 2:02 pm

Looks like it might need a new head. I pulled the #2 injector and it looks like it has a brass sleeve in where the injector sits. It looks like it has a crack coming from the base of the fuel injector. Cant upload a pic here , will try the crd facebook page.

Tree Catcher · **Posted:** Sun Jun 27, 2021 3:10 pm

Looks like its running like it should. I replaced the #1 crush washer, went on to #2 and there was no washer there. I cleaned it as best as i could, saw the crack in the head and said screw it, lets put it back together. Started it up and it sounds normal, took it for a short drve and its back to its happy self. Looks like I will give it to my son and tell him to have our traveling CRD mechanic do the work, unless he has several friends that are mechanically inclined. My son is in the Navy and might know of someone or just have Geordi take care of it when he is on his next trip out west. Glad its fixed now, I cant believe that I sent it to two different shops and they couldn't fix it.

rankom · **Posted:** Sun Jun 27, 2021 6:31 pm

proper procedure for this is to use that tool which I sent prior. clean it all properly, install copper washer, and torque injector hold down bolt to 18ft/lbs. if you did strip injector threads in cylinder head its no big deal just install the helicoil and do the same procedure again and call it done.

WWDiesel · **Posted:** Sun Jun 27, 2021 9:26 pm

rankom wrote:

proper procedure for this is to use that tool which I sent prior. clean it all properly, install copper washer, and torque injector hold down bolt to 18ft/lbs. if you did strip injector threads in cylinder head its no big deal just install the helicoil and do the same procedure again and call it done.

Just curious, where are you getting 18 ft. lbs from, the Factory Service Manual lists 32.4 N·m (24 ft. lbs.)?
I even checked the manual for the 2.5 diesel, and it listed the same torque specifications.

rankom · **Posted:** Mon Jun 28, 2021 8:48 pm

yes WW im aware of the service manual torque specs. but in this case im concerned about damaging the threads, if this was a cast iron head there would be no issues but I know many guys stripped threads into aluminum going around 24+ft/lbs. by the way cummins 8.3 uses exactly the same setup and same copper washer and torque is 18ft/lbs.

krb · **Posted:** Thu Jul 15, 2021 11:42 am

I finally got my leaky #4 injector out. Acetone was my friend.

Used the seat cleaning/dressing tool WW mentioned and so far so good, with about a hundred miles so far.

I torqued the retaining bolt to 24ftlbs per the FSM BTW.

WWDiesel · **Posted:** Thu Jul 15, 2021 12:19 pm

krb wrote:

I finally got my leaky #4 injector out. Acetone was my friend.
Used the seat cleaning/dressing tool WW mentioned and so far so good, with about a hundred miles so far.
I torqued the retaining bolt to 24ftlbs per the FSM BTW.

That is great news indeed; always very nice to read good outcomes... :-)r

rankom · **Posted:** Thu Jul 15, 2021 10:05 pm

WWDiesel wrote:

krb wrote:

I finally got my leaky #4 injector out. Acetone was my friend.
Used the seat cleaning/dressing tool WW mentioned and so far so good, with about a hundred miles so far.
I torqued the retaining bolt to 24ftlbs per the FSM BTW.

That is great news indeed; always very nice to read good outcomes... :-)r

same here. when I did my injectors back in 2013 at 100k miles and now im at 140k miles no leaks so far and I used the same tool and torqued it to 18ft/lbs, just because.

krb · **Posted:** Fri Jul 16, 2021 6:19 am

Forgot to mention I also used a shotgun bore brush too which helped immensely with getting the injector well clean.

Stuck #4 fuel injector

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