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Fuel Injectors: Removal

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  1. Disconnect negative battery cable. On vehicles with dual batteries, see DUAL BATTERIES  under MISCELLANEOUS. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE .
  2. Remove the valve cover.

    1. Left

      • Remove air cleaner assembly. See AIR CLEANER  under AIR INDUCTION SYSTEMS.
      • Remove turbocharger intake tube. See TURBOCHARGER INTAKE TUBE  under AIR INDUCTION SYSTEMS.
      • Remove injection driver module. See INJECTOR DRIVER MODULE  under COMPUTERIZED ENGINE CONTROLS. Remove injector driver module mounting bracket. See Fig 1.
      • Disconnect glow plug harness connector and position aside. Remove oil level tube retaining nut and position tube aside. See Fig 2.
      • Noting position of stud bolts, remove valve cover. See Fig 3.

    2. Right

      • Remove right fender splash shield. Loosen clamps at charge air cooler and turbocharger. Remove charge air tube. See Figure.
      • Disconnect wiring retainer from valve cover stud bolt. Remove glow plug control module. See GLOW PLUG MODULE  under COMPUTERIZED ENGINE CONTROLS.
      • On vehicles with automatic transmission, remove transmission fluid level indicator. Remove retaining nut and disconnect transmission fluid fill tube from stub tube and position it aside. See Figure.
      • Noting position of stud bolts, remove valve cover. See Fig 3.
  3. Disconnect fuel injector electrical connector. See Fig 4.
  4. Using Quick Release Coupling Disconnect Tool, disconnect high pressure oil rail supply line at high pressure oil rail. See Fig 5.
  5. Remove high pressure oil rail bolts and remove high pressure oil rail. See Fig 6.
  6. Using High Pressure Line Disconnect Tool, disconnect and remove the high pressure oil supply line. See Fig 7.
  7. Using a 19-mm socket, push fuel injector electrical connector out of rocker arm carrier. See Fig 8.
    8. NOTE: There is no need to drain fuel rail. If engine oil is found in the engine coolant or engine coolant is found in the combustion chambers, new injector sleeves may need to be installed. See FUEL INJECTOR SLEEVE .
  8. Remove fuel injector hold-down bolt, fuel injector hold down and fuel injector. See Fig 9.
Fig 1: Removing & Installing Injector Driver Module Mounting Bracket
G00250920Courtesy of FORD MOTOR CO.
Fig 2: Repositioning Glow Plug Harness & Oil Level Tube
G00250922Courtesy of FORD MOTOR CO.
Fig 3: Removing & Installing Valve Cover (Left Shown; Right Is Similar)
G00250921Courtesy of FORD MOTOR CO.
Fig 4: Removing & Installing Fuel Injector Electrical Connector
G00250923Courtesy of FORD MOTOR CO.
Fig 5: Disconnecting High Pressure Oil Rail Supply Line At High Pressure Oil Rail
G00250924Courtesy of FORD MOTOR CO.
Fig 6: Removing & Installing High Pressure Oil Rail
G00250925Courtesy of FORD MOTOR CO.
Fig 7: Disconnecting High Pressure Oil Rail Supply Line At Rocker Arm Carrier
G00250926Courtesy of FORD MOTOR CO.
Fig 8: Removing & Installing Fuel Injector Electrical Connector At Rocker Carrier
G00250927Courtesy of FORD MOTOR CO.
Fig 9: Removing & Installing Fuel Injector Hold-Down Bolt
G00250928Courtesy of FORD MOTOR CO.
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