Injector cups and tools!! - Diesel Forum - TheDieselStop.com
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99 & up 7.3L Power Stroke Engine and Drivetrain Discussion of the 99 & up 7.3L Power Stroke diesel engine and drivetrain in the 1999-Up Super Duty trucks and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 7.3L Power Stroke engine.

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Old 10-08-2006, 09:16 AM   #1 (permalink)
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Injector cups and tools!!

Diesel fuel in coolant.Looking to replace injector cups and maybe injectors while they are out. Any help from how much for the cups, advice on how to do it, to what kind of injectors to buy would be appreciated.I read somewhere that there are tools on this site that can be rented or borrowed.As for injectors, lookin for a little more horsepower nothing big. Been lurking on this site for 3 years, finally need help that I just can't find. [img]/ubbthreads/images/graemlins/shrug.gif[/img]
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Old 10-08-2006, 09:42 PM   #2 (permalink)
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Re: Injector cups and tools!!

Any help? Can't seem to find anything on a search either.
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Old 10-08-2006, 09:52 PM   #3 (permalink)
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Re: Injector cups and tools!!

Go to napa and pick up a drum brake tool(5 bucks)that will help pop out the injectors. Small ID tubing will help with the glow plugs. I have not done cups yet so can't help you there.
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Old 10-09-2006, 04:19 PM   #4 (permalink)
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Re: Injector cups and tools!!

Denny thanks , I've changed glowplugs and pulled injectors. Just never changed the cups or sleeves as some call them.Need the tools and a little guidance, maybe just a little moral support. Thanks
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Old 10-09-2006, 06:22 PM   #5 (permalink)
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Re: Injector cups and tools!!

Welcome to TheDieselStop [img]/ubbthreads/images/graemlins/smile.gif[/img]

You might need a little more than moral support.

The tool is like a tap that threads into the cup, then you screw a slide hammer puller on top to get the cups out.
Putting them back in takes an injector shaped drift.

I think there's probably some tools floating around out there, but don't know where. Best bet would be to ask around in your local area.

If you decide to do it yourself, shoot me a PM, and I can probably come up with the instructions. IIRC, the heads have to come off to do them all. If you're lucky and it's a forward cylinder that has the problem, you may be able to do it with the heads in place. The back ones are tough to get to.
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Old 10-09-2006, 08:03 PM   #6 (permalink)
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Re: Injector cups and tools!!

Thanks klhansen. That helps a bunch, but rather than pay someone to do the testing and changing just one . I was thinking of just changing them all, myself.You don't think the rear ones will come out at all or are they just a bear to get at. Not really sure if I want to pull the heads off though.Will the heads come off without pulling the motor.Thanks again.
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Old 10-09-2006, 08:18 PM   #7 (permalink)
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Re: Injector cups and tools!!

You didn't say what year your truck is (assuming a Superduty since you posted in the 99+ forum). I don't think #'s 7&8 can be done with the heads in place. The cowl edge is just too far forward to get the puller in place.

Yes, heads can be pulled without pulling the engine, but they aren't easy to get out either.

Good luck
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Old 10-09-2006, 09:24 PM   #8 (permalink)
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Re: Injector cups and tools!!

I had the same problem a month ago. I found out that the o-rings that separate the fuel area from the coolant area were worn. All 8 of them. I thought that was strange, but they all wore the same. I would definitely pull all 8 injectors and replace the o-rings. My cups were looking great. Probably didn't need to replace them the mechanic said. I had the heads re-worked too. The heads were milled on both the "bottom" and the exhaust side.

I know it is a huge expense, but I would also recommend to have the heads pulled off and gone through. If you are getting fuel in your coolant like I was, which wasn't bad or a lot I should say, you can almost guarantee that the o-rings are going bad on all injectors.

Hope it is under warranty. Mine weren't and I about sold the truck because of the price tag!
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Old 10-09-2006, 09:39 PM   #9 (permalink)
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Re: Injector cups and tools!!

Are you saying to just replace the o-rings on the injectors and not replace the cups? I don't know if it is the cups for sure , I am just assuming. Can fuel get into the coolant and not have cracked cups? Oh and it only has 50k on it , but i'm the third owner. Warranty prolly won't apply.
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Old 10-09-2006, 11:12 PM   #10 (permalink)
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Re: Injector cups and tools!!

Cracked injector cups is the only way fuel can get into the coolant. There is no o-ring separating the fuel from coolant. Injector o-rings only separate fuel and oil, coolant is nowhere near the o-rings.

I would try to diagnose which bank has the leaking cup also, by either removing all injectors and pressurizing the cooling system checking for coolant in the cups, or by isolating the fuel rails and pressuring with shop air watching for air bubbles in the cooling system. The later method would still require you to pull injectors only on that bank and pressure the cooling system to find the bad cup.

As for warranty, you would have a 5yr/100k on engine only. I see you have a 2000, which would have ran out on the 5yr part last year. The only way it may be warranty, is if you bought an extended warranty when you purchased the vehicle.

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Old 10-09-2006, 11:53 PM   #11 (permalink)
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Re: Injector cups and tools!!

I've pulled the heads with the engine in the truck and I've pulled the engine to deal with the heads. Having done it both ways, I'll tell you that I would pull the engine in a heartbeat and never again fight with the heads with the engine still in the truck. Even if you get the heads off with the block still in, reinstalling them is a total PITA and you run the risk of ruining the head gaskets when you end up dropping a 17 bazillion pound head on top of them. Most importantly, it's faster for me to just pull the engine.
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Old 10-10-2006, 09:01 PM   #12 (permalink)
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Re: Injector cups and tools!!

Hey guys thanks for all the great advice. Nobody told me what I wanted to hear though( how easy it's gonna be ). I think I'll try myself to diagnose which one , and hope it's a forward one. What do you all suppose the chances of that are? Slim or none? Cover me boys , I'm goin in. Thanks to everyone.
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Old 10-10-2006, 09:19 PM   #13 (permalink)
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Re: Injector cups and tools!!

I have done #8 with the head on. True, you can"t use a slide hammer.
I cut a piece of steel with a hole in the middle, layed it across the rockers and threaded a bolt into the removal tool. As you tighten the bolt, the tool pulls the cup up. It came out without putting much pressure on the rockers or I would have stopped.
The tool was 5/8 fine thread, so I got a couple different length bolt to find one that would work right using it as a puller.
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Old 10-10-2006, 09:23 PM   #14 (permalink)
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Re: Injector cups and tools!!

[ QUOTE ]
I have done #8 with the head on. True, you can"t use a slide hammer.
I cut a piece of steel with a hole in the middle, layed it across the rockers and threaded a bolt into the removal tool. As you tighten the bolt, the tool pulls the cup up. It came out without putting much pressure on the rockers or I would have stopped.
The tool was 5/8 fine thread, so I got a couple different length bolt to find one that would work right using it as a puller.

[/ QUOTE ]

I've done similar things, but didn't think of that one.

Good thinking, and thanks for the tip.
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Old 10-10-2006, 09:27 PM   #15 (permalink)
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Re: Injector cups and tools!!

Forgot to mention before, I borrowed the tools from the International dealer I deal with. Maybe you might a have friend of a friend that works at a dealer or something? I have seen the tools for sale somewhere before, I believe maybe it was one of TDS sponsors but I can't remember.
And whoever thinks they fixed fuel in the coolant with new o-rings, make plans to pull your inj. again because it is not fixed.
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