Fuel Injectors - Early Build: Removal

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Remove the valve cover. Refer to ENGINE - 6.0L DIESEL .
Disconnect the fuel injector electrical connector.

Fig 1: Disconnecting Fuel Injector Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the high-pressure oil rail supply line at the high-pressure oil rail.

Fig 2: Disconnecting High-Pressure Oil Rail Supply Line At High-Pressure Oil Rail
Courtesy of FORD MOTOR CO.
Remove the bolts and the high-pressure oil rail.

Fig 3: Removing Bolts And High-Pressure Oil Rail
Courtesy of FORD MOTOR CO.
Disconnect and remove the high-pressure oil supply line.

Fig 4: Removing High-Pressure Oil Supply Line
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.

Fig 5: Pushing Fuel Injector Electrical Connector

Courtesy of FORD MOTOR CO.

Using a 19 mm (0.74 in) socket, push the fuel injector electrical connector out of the rocker arm carrier.

CAUTION: To prevent engine damage, do not use air tools to remove the fuel injectors. The clip 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. 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 6: Removing Bolt, Fuel Injector Hold-Down Clamp And Fuel Injector

Courtesy of FORD MOTOR CO.

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