Repair 7

How to Change Injectors on 7 3 Diesel

The 7.3-liter diesel engine made by Ford from 1994 to 2002 is commonly found in heavy trucks from this period. This engine employs fuel injection to send fuel into the engine under high pressure. Each cylinder of the engine has its own fuel injector, which delivers the fuel in an electronically-controlled sequence. You can remove and install the fuel injectors on this diesel engine individually with a special tool.

Instructions

1

Disconnect the mounting bolts for the valve cover with a socket wrench and remove the valve cover. Detach the wiring harnesses from the fuel injectors.

2

Disconnect the oil rail drain plugs and fuel rail drain plugs with a socket wrench. Disconnect the oil deflector by removing its retaining screw.

3

Remove the mounting bolt on the outboard side of the fuel injector with a socket wrench. Disconnect the retaining hardware from the heater distribution box, including the screws, nuts and clips. Remove the heater distribution box.

4

Connect the injector remover no. T94T-9000-AH1 to the fuel injector plate with the injector removers screw. Tighten the screw to lift the fuel injector from the injector bore. Discard the copper washers for the fuel injector.

5

Clean the injector bore with the rotunda injector sleeve brush and a shop towel. Mount a new copper washer to the new fuel injector and coat the fuel injector with engine oil to lubricate it.

6

Place the fuel injectors into the injector bore and ensure that you properly seat the O-rings. Position the injector replacer No. T94T-9000-AH2 between the fuel injector and its hold-down plate. Tighten the bolt on the injector replacer to fully seat the fuel injector into the injector bore.

7

Perform steps one through three in reverse order to complete the fuel injector replacement. Torque the retaining screw on the oil deflector to 108 inch-pounds with a torque wrench. Torque the fuel rail drain plugs to 96 inch-pounds and torque the oil rail drain plugs to 53 inch-pounds.