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Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 71 (Fuel System & Engine Controls - 6.0L Diesel -- F250-F550 Super Duty) >> Removal And Installation >> Fuel Injectors >> Removal

Fuel Injectors: Removal

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

  1. Remove the valve cover. For additional information, refer to ENGINE - 6.0L DIESEL .
  2. Disconnect the fuel injector electrical connector.
    Fig 1: Identifying Fuel Injector Electrical Connector & Retainer Clip
    G03887113Courtesy of FORD MOTOR CO.

    3. Late build vehicles 

  3. Remove the crankcase-to-head tube assembly.
    • Remove and discard the D-ring seals.
      Fig 2: Removing Crankcase-To-Head Tube Assembly
      G03887376Courtesy of FORD MOTOR CO.

    4. All vehicles 

    NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.
    NOTE: Use a tool like the KD Tool #58965 or Lisle T30 to avoid interference with the evaporator case.
    Fig 3: Identifying Bolts And High-Pressure Oil Rail
    G03887377Courtesy of FORD MOTOR CO.
  4. Remove the bolts and the high-pressure oil rail.

    5. Early build vehicles 

    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.
  5. Remove the crankcase-to-head tube.
    • Remove and discard the D-ring seal.
      Fig 4: Identifying Crankcase-To-Head Tube
      G03887379Courtesy of FORD MOTOR CO.

    6. Late build vehicles 

    CAUTION: Use care not to deform the lower crankcase-to-head tube during removal. If the tube is damaged, a new tube must be installed.
    NOTE: Use a shop towel and metal brake parts cleaner to remove the oil residue prior to removing.
  6. If the crankcase-to-head tube separated, using a pair of soft-jawed pliers, remove the lower crankcase-to-head tube.
    • Remove and discard the D-ring seal.
      Fig 5: Removing Lower Crankcase-To-Head Tube
      G03887378Courtesy of FORD MOTOR CO.

    7. All vehicles 

    CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.
    Fig 6: Removing Fuel Injector Electrical Connector
    G03887380Courtesy of FORD MOTOR CO.
  7. Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
  8. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
    9. 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. For additional information, 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 7: Locating Bolt, Fuel Injector Hold-Down Clamp And Fuel Injector
    G03887381Courtesy of FORD MOTOR CO.
  9. Remove the bolt, fuel injector hold-down clamp and fuel injector.
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