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Fuel Injectors: Removal

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Contact with exposed fuel injector wiring, if energized, may result in electric shock. Use care when working on or around energized fuel injector wiring. Fuel injector wiring supplies high voltage to operate the fuel injectors. Failure to follow this instruction may result in serious personal injury.
WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
NOTE: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel openings to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.
  1. WARNING: Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.

    Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .

  2. Disconnect the battery ground cables. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Remove the RH or LH fender splash shield. For additional information, refer to FRONT END BODY PANELS .
  4. NOTE: The glow plug module must be removed if the RH fuel injectors are being removed.

    If necessary, remove the glow plug module. For additional information, refer to GLOW PLUG SYSTEM - 6.7L DIESEL .

  5. NOTE: It may be necessary to unthread the engine sound shield retainers from the engine.

    Remove the 5 RH or 5 LH engine sound shield retainers and the RH or LH engine sound shield.

  6. Disconnect the fuel injector electrical connector.
  7. Disconnect the 3 fuel charging wiring harness retainers from the fuel rail.
    • Position aside the fuel injector wiring harness.
  8. Push down on the tabs and pull up on the center of the fuel injector return hose fitting to unlock the fitting.
    • Disconnect the fuel injector return hose fitting from the fuel injector.
      Fig 1: Pulling Up Fuel Injector Return Hose Center Fitting
      G07481735Courtesy of FORD MOTOR CO.
  9. NOTE: The fuel pressure control valve electrical connector must be disconnected to remove the cylinder No. 8 fuel injector.

    If necessary, disconnect the fuel pressure control valve electrical connector.

  10. NOTE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components.
    NOTE: The fuel injector supply tube cannot be reused.

    Remove and discard the fuel injector supply tube.

  11. NOTE: The fuel injector hold-down clamp bolts are torque-to-yield and cannot be reused.

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

    • Remove the fuel injector hold-down clamp.
  12. Install the Injector Removal Tool.
    1. Install the Injector Removal Tool to the fuel injector and fully hand-tighten the Injector Removal Tool mounting bolt.
    2. Install the allen-head push bolt and tighten to remove the fuel injector.
    3. Remove the Injector Removal Tool mounting bolt and the lower portion of the Injector Removal Tool.
    4. Remove and discard the O-ring seal and the copper combustion gasket from the fuel injector.
    5. Remove and discard the fuel injector return fuel O-ring.
      Fig 2: Identifying Injector Removal Tool
      G07481736Courtesy of FORD MOTOR CO.
  13. NOTE: The PCM is programmed with an IQA code for each fuel injector. Note the fuel injector cylinder location.

    Install the fuel injector into the Fuel Injector Cup and store the fuel injector in the corresponding cylinder location in the Fuel Injector Holding Rack.

  14. NOTE: Use the notch in the valve cover to aid in removing the fuel injector-to-valve cover seal.

    Remove the fuel injector-to-valve cover seal out of the valve cover using a screwdriver.

    Fig 3: Locating Fuel Injector-To-Valve Cover Seal
    G08601869Courtesy of FORD MOTOR CO.
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