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Fuel Injectors: Removal

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the air cleaner assembly and resonator. Drain the fuel from the cylinder heads. Loosen the drain plugs, located at the rear of each cylinder head.
  2. If removing injector No. 3 or 5, disconnect the A/C compressor clutch wire. Raise and support the vehicle. Loosen the right side motor mount nuts. Remove the left side engine mount-to-engine bolts. Raise the engine. Remove the left side engine mount-to-crossmember nuts. Remove the left side engine mount. Lower the engine until the oil pan is resting on the crossmember. Lower the vehicle.
  3. Remove the valve cover. See VALVE COVERS . Remove the fuel charging wiring. Remove the oil drain plugs. See Fig 1.
    4. NOTE: Rocker arm removed for clarity. Rocker arm removal is not required for fuel injector removal and installation. The inboard fuel injector hold-down bolts DO NOT require removal to remove the fuel injectors.
  4. Remove the bolt and the oil deflector from the fuel injector hold-down plate. See Fig 2. Remove the outboard fuel injector hold-down bolts. See Fig 3.
    5. NOTE: When removing the fuel injectors, it is important that the injector tip copper washer is removed from the injector bore. If the copper washer is not on the injector when removed from the cylinder head, make sure to remove it from the injector bore.
  5. Using the Injector Remover (303-491, T94T-9000-AH1), remove the fuel injector. See Fig 4. Place the fuel injector into the Injector Protective Sleeve and Holding Rack (303-DS113, D94T-9000-E). See Fig 5.
  6. If engine coolant is found in the combustion chambers then NEW injector sleeves may need to be installed. To install NEW fuel injector sleeves, the cylinder heads must be removed from the vehicle. Remove the cylinder heads.
    7. NOTE: The special tools listed in the next step, are part of a Injector Sleeve Remover Set (303-DS105, D94T-9000-B) and are not named separately by the manufacturer.
  7. Place a plastic cap or a small piece of cork, to act as a stop, in the injector sleeve before installing Special Tool (303-D107, D94T-9000-B2). This will prevent damage to the cylinder head bore.
  8. Insert Special Tool (303-D106, D94T-9000-B1) and Special Tool (303-D107, D94T-9000-B2) into the cylinder head fuel injector bore. Tighten Special Tool (303-D106, D94T-9000-B1) 1-1/2 to 2 turns.
  9. Attach the Slide Hammer (100-001, T50T-100-A) to Special Tool (303-D106, D94T-9000-B1), and remove the fuel injector sleeve from the cylinder head fuel injector bore. Discard the sleeve.
  10. Using the injector sleeve brush, part of Injector Sleeve Brush Set (303-DS110, D94T-9000-D), remove sealant residue and all foreign material from the cylinder head fuel injector bore. See Fig 6.
Fig 1: Locating Oil Rail Drain Plug & Fuel Injector Retaining Bolt
G95H27877Courtesy of FORD MOTOR CO.
Fig 2: Locating Oil Deflector, Oil Deflector Retaining Bolt Fuel Injector Shoulder Bolt & Rocker Arm Bolts
G97B03754Courtesy of FORD MOTOR CO.
Fig 3: Removing & Installing Fuel Injector Outboard Bolts
G00209397Courtesy of FORD MOTOR CO.
Fig 4: Removing Fuel Injector
G00209398Courtesy of FORD MOTOR CO.
Fig 5: View Of Fuel Injector Protective Sleeve & Holding Rack
G00209399Courtesy of FORD MOTOR CO.
Fig 6: Identifying Injector Sleeve Brush
G00209400Courtesy of FORD MOTOR CO.
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