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Fuel Injectors: Removal

WARNING: This page is about a different car, the 2003 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect negative battery cable. On vehicles with dual batteries, see DUAL BATTERIES  under MISCELLANEOUS. Remove air cleaner, inlet duct and resonator. See AIR INTAKE RESONATOR  under AIR INDUCTION SYSTEMS. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE  .
  2. Loosen cylinder head drain plugs, located at the rear of each cylinder head, and drain the fuel from the cylinder heads. See Fig 1 .
  3. If removing injector No. 3 or 5, disconnect A/C compressor clutch wire. Raise and support vehicle. Support engine. Loosen right motor mount nuts. Remove left engine mount-to-engine bolts and raise engine. Remove left engine mount-to-crossmember nuts and remove left engine mount. Lower engine until oil pan is resting on crossmember.
  4. Remove the valve cover.

    1. Left

      Remove oil fill tube. Disconnect fuel injector/glow plug 9-pin connector retaining clip and disconnect connector. Remove 10 valve cover bolts and remove valve cover.

    2. Right

      Remove oil level indicator tube nut. Pull upward and remove tube. Disconnect fuel injector/glow plug 9-pin connector retaining clip and disconnect connector. Remove nut and resonator bracket. Remove 10 valve cover bolts and remove valve cover.
  5. Disconnect glow plugs electrical connectors. Disengage fuel injectors attaching clip and disconnect fuel injector connectors. Remove electrical connector retaining clip and disconnect electrical connector. Remove the electrical connector from valve cover gasket.
  6. Remove oil drain plugs in the cylinder head. See Fig 2 . Remove bolt and oil deflector from fuel injector hold-down plate. See Fig 3 . Remove outboard fuel injector hold-down bolts. It is not necessary to remove inboard fuel injector hold-down bolts to remove fuel injectors.
  7. Using Injector Remover Fulcrum, remove fuel injector from cylinder head. See Fig 4 . It is important that the injector tip copper washer is removed from the injector bore. If the copper washer is not on the injector when removed from the cylinder head, make sure to remove it from the injector bore. Place fuel injector into the Injector Protective Sleeve and Holding Rack.
    8. NOTE: If engine coolant is found in the combustion chambers then new injector sleeves may need to be installed. To install new fuel injector sleeves, cylinder heads must be removed from vehicle. See appropriate REMOVAL & INSTALLATION article.
  8. Insert special tool 303-D106 (D94T-9000-B1) and special tool 303-D107 (D94T-9000-B2) of Injector Sleeve Remover Set into the cylinder head fuel injector bore. Tighten special tool 303-D106 (D94T-9000-B1) 1-1/2 to 2 turns. Attach Impact Slide Hammer to special tool 303-D106 (D94T-9000-B1) and remove the fuel injector sleeve from the cylinder head fuel injector bore. See Fig 5 . Discard the sleeve.
  9. Using the Injector Sleeve Brush Set, remove sealant residue and all foreign material from the cylinder head fuel injector bore.
Fig 1: Removing & Installing Cylinder Head Fuel Drain Plugs
G00248223Courtesy of FORD MOTOR CO.
Fig 2: Removing & Installing Oil Rail Drain Plug
G95C35859Courtesy of FORD MOTOR CO.
Fig 3: Removing & Installing Injector Oil Deflector
G00248224Courtesy of FORD MOTOR CO.
Fig 4: Using Fuel Injector Remover Set
G95F35860Courtesy of FORD MOTOR CO.
Fig 5: Removing Fuel Injector Sleeve
G00248225Courtesy of FORD MOTOR CO.
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