Removal And Installation

REMOVAL 

1. Disconnect and isolate the negative battery cable(s). Refer to STANDARD PROCEDURE .
2. Remove cylinder head cover and the gasket. Refer to COVER(S), CYLINDER HEAD, REMOVAL AND INSTALLATION, 6.7L .
3. Remove the high pressure fuel tubes. Refer to TUBE(S), FUEL, REMOVAL AND INSTALLATION .

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4. Remove the fuel injector connector nut (5).

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5. Install the High Pressure Connector Remover (special tool #9015, Remover, High Pressure Connector) (4) onto fuel injector connector tube located in cylinder head.

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   NOTE:

   High pressure connectors are reusable but must be paired with the same injector (not swapped to another injector). When installing new injectors, new high pressure connectors must be used.

6. Using the Thread High Pressure Connector Remover (special tool #9015, Remover, High Pressure Connector) (2), pry and remove the fuel injector connector tube(s) (4) from the cylinder head.
   NOTE:

   Do not remove the intake rockers, as this will increase the amount of time required for hydraulic lifters to bleed down after reinstalling the rockers. Engine damage may occur if these instructions are not followed.

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7. Remove exhaust rocker lever bolt(s) (3), exhaust rocker lever(s) (2), and exhaust crosshead(s) (1). Mark each component so they can be installed in their original position.

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8. Remove the fuel injector bolts (1) and the hold-down clamp.

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   NOTE:

   The rocker housing support bridge is bolted to the top of cylinder head. The mounting stud bolt from Fuel Injector Removal/Installer (special tool #9010B, Remover/Installer, Fuel Injector) was meant to temporarily replace a rocker housing mounting bolt (1).

9. Remove the necessary rocker housing mounting bolt (1).

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   CAUTION:

   Fuel Injector Removal/Installer 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 injectors with any other device. Damage to injector will occur.

10. Install and tighten the 2-piece mounting stud (3) of Fuel Injector Removal/Installer (special tool #9010B, Remover/Installer, Fuel Injector), to the rocker housing (4). If removing the No. 6 fuel injector, separate the 2-piece mounting stud (3). Install the lower half of the mounting stud (3) to the center of the rocker housing bridge (4) and the upper half of the mounting stud to the lower half.
11. Position the tool handle (1) to the mounting stud (3) and install handle nut (2). Leave handle nut (2) loose to allow a pivoting action.

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12. Position lower part of the clamshell halves (1), opening facing the intake rocker/crosshead to allow for tool clearance, to the sides of the fuel injector (2) (wider shoulder to bottom). The upper part of the clamshell halves should also be positioned into the machined shoulder on the handles pivoting head.
13. Slide the retainer sleeve (3) over the pivoting handle head to lock the clamshell halves (1) together. Be sure the handle pivot nut is loose.
14. Depress the handle of the Fuel Injector Removal/Installer (special tool #9010B, Remover/Installer, Fuel Injector) (2) downward to remove the fuel injector straight up from the cylinder head bore.

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15. Remove and discard injector sealing washer (2) and O-ring (1). The injector sealing washer should be located on the tip of the injector, or it may have remained in the injector bore.

INSTALLATION 

1. Thoroughly clean the fuel injector cylinder head bore. Blow out bore hole with compressed air.

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2. The bottom of the fuel injector is sealed to the cylinder head bore with a bronze sealing washer (shim) (1) of a certain thickness. A NEW  shim (1) with correct thickness must always be re-installed after removing the injector. Measure the thickness of the injector shim (1). Shim Thickness: 1.5 mm (.060") 

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   NOTE:

   When replacing the injector sealing washer (1), only the serrated edge style washer must be used; not a smooth edge style washer.

3. Install the NEW  shim (2) (washer) to the bottom of the injector. Apply a light coating of clean engine oil to the washer. This will keep the washer in place during installation.
   NOTE:

   New fuel injectors come with a new shim (2) and O-ring (1) pre-installed.

4. Install the NEW  O-ring to the fuel injector. Apply a small amount of clean engine oil to the O-ring and injector bore.

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5. Install the fuel injector into the cylinder head with the male (high-pressure) connector port facing the intake manifold. Push down on the fuel injector mounting flange to engage the O-ring and seat injector.
6. Tightening Sequence:
   1. Install fuel injector hold-down clamp (mounting flange) bolts. Be sure the clamp is perpendicular to the injector body. Do a preliminary tightening of these bolts to 2 N.m (18 in. lbs.). This preliminary tightening insures the fuel injector is seated and centered. 
   2. After tightening, relieve bolt torque, but leave both bolts threaded in place.

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      NOTE:

      High pressure connectors (8) are reusable but must be paired with the same injector (not swapped to another injector). When installing NEW  injectors, NEW  high pressure connectors (8) must be used.

   3. Install the fuel injector connector(s) (8) and fuel injector connector nut(s) (5). Do a preliminary tightening of the connector nut(s) (5) to 15 N.m (11 ft. lbs.).
   4. Alternately tighten injector hold-down bolts to 8 N.m (71 in. lbs.).
   5. Do a final tightening of the fuel injector connector nut(s) (5) to 55 N.m (41 ft. lbs.).
7. Install the high pressure fuel tubes. Refer to TUBE(S), FUEL, REMOVAL AND INSTALLATION .

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8. Install the necessary rocker housing mounting bolt (1) and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .

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9. Install the cylinder head cover gasket (2).

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10. Connect the fuel injector solenoid wires and nuts (1) to the top of injector (2). Tighten the connector nuts to 1.50 N.m (13 in. lbs.). Be very careful not to overtighten these nuts. 

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11. Remove the bolts (1) and the bell housing access cover (2).

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12. Using the Barring Tool (special tool #7471B, Barring Tool) (1) or equivalent, rotate the crankshaft until the engine is at bottom dead center (BDC).

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13. The engine is at bottom dead center when the top dead center (TDC) mark on the damper is aligned to the 6:00 o'clock position and is visible from underneath the vehicle or the alignment pin (1) is at the 6:00 o'clock position.

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    CAUTION:

    Before installing the rocker arms, the engine must be at bottom dead center (BDC). Failure to rotate the engine to bottom dead center will result in valve to piston contact when the rocker arms are installed.

    CAUTION:

    The rocker arm pedestal mounting bolts must be torqued down in stages to allow adequate time for the hydraulic lifters to bleed down before performing the final installation torque. Failure to allow the lifters to bleed down before applying the final installation torque on the rocker pedestals will cause the valve springs to coil bind, which will weaken the springs and result in valve spring failure.

14. Lubricate the exhaust valve tips and install the crossheads (1) in their original locations.
15. Lubricate the top of the exhaust crossheads (1) and push rod balls and install the exhaust rocker arms (2) with pedestals in their original locations.
    NOTE:

    The push rod balls must be fully seated in the rocker arm cups and hydraulic lifters prior to starting the pedestal bolt torque procedure. This can be verified by slowly rotating the push rod - it should rotate smoothly without binding or excessive force required.

    NOTE:

    Engine temperature must be above 50°F (10°C) to perform the rocker torque procedure.

16. Tighten the exhaust pedestal bolt(s) (3) as follows:
    1. Tighten the bolts to 7 N.m (62 in. lbs.).
    2. Allow the hydraulic lifters 15 minutes to initially bleed down. During this time frame, do not rotate the crankshaft or perform any further tightening on the pedestals.
    3. Tighten the bolts to 36 N.m (27 ft. lbs.).
    4. After performing the final torque, allow the hydraulic lifters 15 minutes to finish bleed down before rotating or starting the engine. The remaining items that were removed can be installed during this time period.
17. Install the cylinder head cover gasket and the cylinder head cover. Refer to COVER(S), CYLINDER HEAD, REMOVAL AND INSTALLATION, 6.7L .
18. Connect the negative battery cable(s). Refer to STANDARD PROCEDURE .
19. Using the wiTECH electronic service tool, perform the fuel injector compensation correction reset function for any injectors that were replaced. It is not necessary to perform this function unless a new injector, or multiple new injectors, have been installed.

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20. Using the Barring Tool (special tool #7471B, Barring Tool) (1) or equivalent, rotate the crankshaft two revolutions (720 degrees). If the hydraulic lifters are sufficiently bled down, the crankshaft will rotate freely. If the crankshaft does not rotate freely, verify that the stepped rocker torque procedure ( step 16) was followed correctly and sufficient hydraulic lifter bleed down time was allowed.
    CAUTION:

    Valve to piston contact will occur if the hydraulic lifters are not properly bled down before the engine is rotated or started.

    CAUTION:

    To prevent damage to valve assemblies, do not run the engine above idle until all hydraulic lifters have filled with oil and have become quiet.

    NOTE:

    The hydraulic lifters will make noise until they have filled with oil.

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21. Install the bell housing access cover (2) and tighten the bolts (1) to the proper specification. Refer to TORQUE SPECIFICATIONS .
22. Start the engine, check for leaks, and allow engine to idle until hydraulic lifters have filled with oil and have become quiet.