Fuel Injector: Service and Repair

Impact Slide Hammer:

Injector Replacer:

Injector Protective Sleeve And Holding Rack:

Injector Remover:

Injector Sleeve:

Injector Sleeve Remover Set:

Injector Sleeve Replacer:

Special Tools Recommended

REMOVAL

1. Remove the valve cover.
2. Remove the fuel charging wiring.







3. Remove the oil drain plugs.







4. Drain the fuel from the cylinder heads.
- Loosen the drain plugs.







5. Remove the bolt and the oil deflector from the fuel injector hold-down plate.

NOTE: Rocker arm removed for clarity.








6. Remove the fuel injector retaining bolts.







7. Using the Injector Remover, remove the fuel injector.

NOTE: When removing the fuel injectors, it is important that all three injector O-rings and the injector tip copper washer are removed from the injector bore.







8. Place the fuel injector into the injector protective sleeve.
9. Place the injector and sleeve into the holding rack.
10. Remove the cylinder heads from the engine.

NOTE: To replace the fuel injector sleeves, the cylinder heads must be removed from the vehicle.







11. Insert the injector sleeve tap and injector sleeve tap pilot into the cylinder head fuel injector bore. Tighten injector sleeve tap 1-1/2 to 2 turns. Attach the Impact Slide Hammer to the injector sleeve tap pilot, and remove the fuel injector sleeve from the cylinder head fuel injector bore.








12. Remove sealant residue and all debris from the cylinder head fuel injector bore, using the injector sleeve brush.

INSTALLATION







1. Position the fuel injector sleeve onto the Injector Sleeve Replacer. Apply Threadlock(R) 262 E2FZ-19554-B or equivalent meeting Ford specification WSK-M2G351-A6 to the fuel injector sleeve.







2. Position the fuel injector sleeve into the cylinder head fuel injector bore. Seat the fuel injector sleeve in the fuel injector bore, using a rubber mallet. Remove Injector Sleeve Replacer tool from the cylinder head fuel injector bore.







3. Clean the fuel injector sleeve and bore, using the fuel injector sleeve brush. Remove any sealant residue from the fuel injector bore.
4. Install new O-rings on the fuel injector. Lubricate the fuel injector and O-rings liberally with clean engine oil.
5. Install the cylinder heads.







6. Using the injector replacer, seat the fuel injector into the cylinder head fuel injector bore.

CAUTION:
- Remove all oil and fuel from the cylinders before installing the fuel injectors. Failure to do so can cause hydrostatic lock, resulting in severe engine damage.
- There are two different fuel injectors used in the 1998 7.3L DI turbo diesel engine: a 49-state injector and the California injector (rate-shape injector). These two injectors must not be interchanged because the powertrain control modules are calibrated to the specific injector. Before replacing any injectors, refer to Vehicle Emission Control Information (VECI) decal for proper injector selection. Failure to do so can cause poor engine performance, high emissions levels and damage to the engine.
- Do not strike the top of the fuel injector to seat the injector in the cylinder head fuel injector bore. Damage to the fuel injector will occur. Use hand pressure on the top of the fuel injector until the fuel injector hold-down plate is flush with the cylinder head.







7. Install the fuel injector retaining bolts.







8. Install the oil deflector on the fuel injector hold-down plate, using the shoulder bolt.







9. Install the oil drain plugs.
10. Position the valve cover gasket onto the cylinder head.
11. Install the fuel charging wiring.
12. Install the valve covers.







13. Tighten the fuel gallery drain plugs.