2004 Ford F-Super Duty 250-550 Fuel Injectors Removal Installation

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Filed Under (Ford) by admin on 22-02-2011

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All vehicles 1. Remove the valve cover. For additional information, refer to Section 303-01C. 2. Disconnect the fuel injector electrical connector. Two-piece head tube 3. NOTE: Some engines may have been updated with a new two-piece crankcase-to-head tube. If the crankcase-to-head tube has been updated it will have a hex head. If the high-pressure oil rail has a hex head, remove the crankcase-to-head tube assembly. Remove and discard the O-ring seals. All vehicles 4. NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components. NOTE: Use a tool like the KD Tool #58965 or Lisle T30 to avoid interference with the evaporator case. Remove the bolts and the high-pressure oil rail. One-piece head tube 5. NOTE: The rings on the crankcase-to-head tube are to be used to pry the tube assembly from the branch tube assembly or the oil rail assembly. Remove the crankcase-to-head tube. Remove and discard the O-ring seal. Two-piece head tube 6. CAUTION: Use care not to deform the lower crankcase-to-head tube during removal. If the tube is damaged, a new tube must be installed. NOTE: Use a shop towel and metal brake parts cleaner to remove the oil residue prior to removing. If the updated crankcase-to-head tube separated, using a pair of soft jawed pliers, remove the lower crankcase-to-head tube. All vehicles 7. CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur. Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier. 8. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug. 9. CAUTION: Failure to account for all snap rings or pieces prior to placing the vehicle back in service can cause engine damage. A missing snap ring can be ingested into the lube oil system, causing severe engine damage. CAUTION: To prevent engine damage, do not use air tools to remove the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole. NOTE: There is no need to drain the fuel rail. NOTE: If engine coolant is found in the combustion chambers, it may be necessary to install a new injector sleeve. For additional information, refer to Fuel Injector Sleeve in this section. NOTE: Use a tool like Snap-On SDMT440 torx to avoid damaging the fuel injector plastic and to avoid interference with the evaporator case. Remove the bolt, fuel injector hold-down clamp and fuel injector. Installation One-piece head tube