Fuel Injectors - Late 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.

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

Fig 2: Removing Bolts And High-Pressure Oil Rail

Courtesy of FORD MOTOR CO.

Remove the bolts and the high-pressure oil rail.

NOTE: The rings on the crankcase-to-head tube are to be used to pry the tube assembly from the branch tube assembly or the oil rail assembly.

Remove the crankcase-to-head tube.
- Remove and discard the O-ring seal.
  
  Fig 3: Removing O-Ring Seal
  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 4: Pushing Fuel Injector Electrical Connector Out Of Rocker Arm Carrier

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.
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. 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 5: 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.

NOTE: If a snap ring or piece of a snap ring is missing from the injector hold-down assembly, it must be located prior to removing the shop towels.

Remove the shop towels.