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Old 01-12-2019, 04:54 PM   #1
javelinadave
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Default 300Tdi Fuel Injector Replacement

I bought a set of fuel injectors from Robert Davis as my truck was getting harder and harder to start and I was rapidly approaching becoming a coal roller. Here is my experience without photos as I was to lazy to take them.

1) Remove the fuel line from the injector top.
2) Remove return line from the side of the injector.
3) Undo the nut that holds the injector bracket and remove the bracket.
4) Replace the nut so it is flush with the top of the stud.
5) Flip over the injector bracket and slide the fork end back onto the injector.
6) With a 1/2" socket extension tap on the end of the bracket and it will pull the injector out of its hole. You may need to tap it with a hammer.
7) After removing all 4 injectors place 4 empty water bottles so they can catch any fuel that you will force out when purging the system of any crap in the lines
8) Turn the engine over for a few seconds and then discard the water bottles.
9) Install a new copper washer onto the end of your new injector (I put a dab of grease to hold it in place) and slide it into place.
10) Reinstall the injector bracket and torque the nut down to factory specs.
11) Replace the little copper washers on both sides of the return line banjo bolts.
12) Bolt the return line onto the new injector sides and torque to factory specs

The start up is the un-nerving part. It takes a bit of cranking and the motor will come to life. Mine had quite a bit of white smoke at first when I went for a test drive. A few miles down the road it turned black then it all disappeared. The truck idles smoother and I don't get the injector tapping noise that I was hearing any more.
The #1 and #2 injectors that I removed looked pretty clean. #3 and #4 looked oily but it was just a blend of carbon and diesel. They say these are wear items so if you have 100k or so on your motor you may look at swapping in new injectors. All and all it took less than 90 minutes. I also swapped in new glow plugs just because. I couldn't get #1 out due to my A/C compressor but I'm pretty sure it is working as it is supposed to.
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Last edited by javelinadave; 01-12-2019 at 10:59 PM.
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