7.3L Power Stroke – FUEL INJECTORS – Removal

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. See FUEL CHARGING WIRING         HARNESS. Remove the oil drain plugs. See Fig. 50.

4. Remove the bolt and the oil deflector from the fuel injector hold-down plate. See Fig. 51.
Remove the outboard fuel injector hold-down bolts. See Fig. 52.

5. Using the Injector Remover (303-491, T94T-9000-AH1), remove the fuel injector. See Fig. 53. Place the fuel                 injector into the Injector Protective Sleeve and Holding Rack (303-DS113, D94T-9000-E). See Fig. 54.

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. See CYLINDER HEADS.

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. 55.