WORK CLEAN!

Wash the engine down, especially the intake side of the engine. MAKE SURE you thoroughly clean out cross over tube detentes in the head. Especially #4- 5- and 6. Use liberal amounts of engine cleaner and a paint brush. Keep doing it until it's spotless. Get dirt in the crossover tube and it's Bye Bye injector.

Lots of compressed air and clean rags. Also, those magnetic bowls are great. Keep them clean. Take your injector out one at a time and cover the rest. Best to leave them packaged until you are ready to install them

Tip. To ensure a good seat of the cross over tube. Don't completely tighten the injector until the cross tube is installed. when both are snug, tighten the injector then finish the tube. Be careful not to cross thread the threads.

Tip. Be sure there is no oil accumulated in the injector retainer bolt holes. You could create hydraulics and snap the bolt long before you reach the 89 in lb. ( I bad. Guilty as charged)

Tip. Inspect all the connectors and wires in the valve cover. When reassembling, make sure they are free and not rubbing against anything at all.

Removal of the injector is this reversed.

INSTALLATION of 24 Valve injector


(1) Inspect fuel injector.
(a) Look for burrs on injector inlet.
(b) Check nozzle holes for hole erosion or plugging.
(c) Inspect end of nozzle for burrs or rough
machine marks.
(d) Look for cracks at nozzle end.
(e) Check nozzle color for signs of overheating.
Overheating will cause nozzle to turn a dark yellow/
tan or blue (depending on overheating temperature).
(f) If any of these conditions occur, replace injector.
(2) Thoroughly clean fuel injector cylinder head
bore with special Cummins wire brush tool or equivalent
(Fig. 22). Blow out bore hole with compressed air.
(3) The bottom of fuel injector is sealed to cylinder
head bore with a copper sealing washer (shim) of a
certain thickness (Fig. 20). A new shim with correct
thickness must always be re-installed after removing
injector. Measure thickness of injector shim (Fig. 21).
Shim Thickness: 1.5 mm (.060”)
(4) Install new shim (washer) to bottom of injector.
Apply light coating of clean engine oil to washer. This
will keep washer in place during installation.
(5) Install new o-ring to fuel injector. Apply small
amount of clean engine oil to o-ring.
(6) Note fuel inlet port on high pressure connector.
This must be positioned towards intake manifold.
Position injector into cylinder head bore being
extremely careful not to allow injector tip to touch
sides of bore. Press fuel injector into cylinder head
with finger pressure only.
(7) Install fuel injector hold down clamp and hold
down bolts. Alternately tighten clamp bolts to 10 N·m
(89 in. lbs.) torque.
(8) Connect injector solenoid wires and nuts to top
of injectors (Fig. 18). Tighten connector nuts to 1.5
N·m (14 in. lbs.). Be very careful not to over tighten
these nuts as damage to fuel injector
will occur.
(9) Install exhaust rocker arm assembly.
(10) Set exhaust valve lash. Refer to Engine.
(11) Install high pressure connector and its
retainer nut. Tighten nut to 50 N·m (37 ft. lbs.)
torque.
(12) Install high pressure fuel line. Refer to Fuel
Line Installation.
(13) Install valve cover. Refer to Engine.
(14) Install breather assembly.
(15) Connect negative battery cables to both batteries

I've been meaning to post this for years now. I could recite this in my sleep.