Fuel Injectors: Removal

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 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 article.
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 Crankcase-To-Head Tube

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.

Remove the bolts and the high-pressure oil rail.

Fig 3: Identifying High-Pressure Oil Rail Bolts

Courtesy of FORD MOTOR CO.

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

Courtesy of FORD MOTOR CO.

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

Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.

Fig 5: Locating Fuel Injector Electrical Connector

Courtesy of FORD MOTOR CO.

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 in this article.

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

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

Fig 6: Identifying Fuel Injector Hold-Down Bolt

Courtesy of FORD MOTOR CO.