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Home >> Ford >> 2002 >> Excursion 5.4 L, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 5 (Engine Removal, Overhaul & Installation -- ECONOLINE, Excursion & F250-F550 Super Duty - Diesel 7.3L (99F E Series & 99F F450/550)) >> Fuel System >> Fuel Injectors >> Removal

Fuel Injectors: Removal

WARNING: This page is about a different variant/trim than selected.
  1. Disconnect negative battery cable. Loosen drain plugs located at rear of each cylinder head. Drain fuel from cylinder heads. On Econoline, if removing injector No. 3 or No. 5, disconnect A/C compressor clutch harness connector. Loosen right engine mount and remove left engine mount. Allow engine to rest on crossmember for clearance. On all models, remove right or left valve cover as necessary. To remove right valve cover, remove drive belt, generator mounting bracket and generator. To remove left valve cover, remove intake ducting, crankcase breather and vacuum hose from vacuum pump.
  2. Disconnect harness connector from valve cover gasket. Remove valve cover bolts and valve cover. Disconnect wiring from fuel injectors. Remove valve cover gasket.
  3. Remove oil rail drain plug and let all oil drain from cylinder head. See Fig 1. Loosen fuel rail plug in cylinder head to release fuel pressure. Remove oil deflector. Remove outer fuel injector retaining bolt. Carefully pry fuel injector out of cylinder head using Injector Remover Fulcrum (303-491). See Fig 2. Ensure all "O" rings and washers are retrieved from injector bore. Place fuel injector in a rack or other protected container.
    Fig 1: Removing Oil Rail Drain Plug
    G95C35859Courtesy of FORD MOTOR CO.
    Fig 2: Using Fuel Injector Remover Set
    G95F35860Courtesy of FORD MOTOR CO.
    NOTE: If oil is in coolant or coolant is in oil, new injector sleeves may need to be installed. Cylinder head removal may be necessary to remove fuel injector sleeve from cylinder head.
  4. If removing fuel injector sleeve from cylinder head is necessary, place a plastic cap or piece of cork in injector sleeve to act as a stop. Install Tools (303-D106 and 303-D107) into plug injector bore. Tighten Tool (303-D106) 1.5-2.0 turns. Attach Tool (100-001) to Tool (303-D106). Remove and discard sleeve.
  5. Clean injector bore using Injector Sleeve Brush (303-D111). Ensure all debris is removed.
NOTE: California and Federal models use different fuel injectors. California injectors have a Yellow identification clip. Federal and Canadian injectors have a Medium Blue identification clip. Replacement injectors may have different color clips. Verify injector application using part numbers. Ensure correct injectors are installed.
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