Fuel Injectors: Removal

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Remove the valve cover. For additional information, refer to ENGINE - 6.0L DIESEL .
Disconnect the fuel injector electrical connector.

Fig 1: Identifying Fuel Injector Electrical Connector & Retainer Clip
Courtesy of FORD MOTOR CO.
Remove the crankcase-to-head tube.
- Remove and discard the D-ring seals.
  
  Fig 2: Locating D-Ring Seals
  Courtesy of FORD MOTOR CO.

NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.

NOTE: Use a tool like the KD Tool #58965 or Lisle T30 to avoid interference with the evaporator case.

Fig 3: Identifying Bolts And High-Pressure Oil Rail

Courtesy of FORD MOTOR CO.

Remove the bolts and the high-pressure oil rail.

NOTE: Use a shop towel and metal brake parts cleaner to remove the oil residue prior to removing.

If the crankcase-to-head tube separated, using the special tool, remove the lower crankcase-to-head tube.
- Remove and discard the D-ring seal.
  
  Fig 4: Identifying Special Tool (303-1164)
  Courtesy of FORD MOTOR CO.

NOTE: Early build cylinder heads, head gaskets, cylinder block, rocker arm carriers and injector hold-down clamps are not interchangeable with late build engines. It is necessary to identify the head style prior to working on the cylinder heads. Early build heads are equipped with injector hold-down clamps with a square end and a T40 Torx® bolt. Late build heads have injector hold-down clamps with a tapered end and a T45 Torx® bolt.

Fig 5: Identifying Injector Hold Down Clamps

Courtesy of FORD MOTOR CO.

Determine if the cylinder heads are early build (left frame of illustration) or late build (right frame of illustration).

CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.

Fig 6: Identifying Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.

CAUTION: Failure to account for all snap rings or pieces prior to placing the vehicle back in service can cause engine damage. A missing snap ring can be ingested into the lube oil system, causing severe engine damage.

CAUTION: To prevent engine damage, do not use air tools to remove the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.

NOTE: There is no need to drain the fuel rail.

NOTE: If engine coolant is found in the combustion chambers, it may be necessary to install a new injector sleeve. For additional information, refer to FUEL INJECTOR SLEEVE .

NOTE: Use a tool like Snap-On® SDMT440 Torx to avoid damaging the fuel injector plastic and to avoid interference with the evaporator case.

Fig 7: Identifying Fuel Injector Hold-Down Bolt

Courtesy of FORD MOTOR CO.

Remove the bolt, fuel injector hold-down clamp and fuel injector.