Bad Injector, How to Replace? - Ford Powerstroke Diesel Forum
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Old 02-07-2007, 03:16 PM
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Bad Injector, How to Replace?

I have a 96' F250. Had an engine diagnostic done, read no. 1 injector bad. Ran test 4 times. Sameresults. I'd like to do it myself, but I'm confused as to how to remove the injector. I know how remove the pass side valve cover, but not the injector. Any special tools needed? Tips? Procedures? Any particular brand replacement injector or stay with fomoco? Thanks y'all. Just looking to save a few bucks.
Chris
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Old 02-07-2007, 03:39 PM
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If you're only replacing one injector - get one cheap from Alliant. They're the injector manufacturer for Ford/International and can be had for around 200bucks.

There is a writeup in the techfiles on Injector Oring replacement - this contains removal and reinstallation of injectors, maybe this can help!

The guy you want to talk to is Marc.
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Old 02-07-2007, 03:43 PM
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This is what I was talking about and it's even on the OBS trucks...

injector o-ring replacement
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Old 02-07-2007, 04:08 PM
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hey its actually a very simple removal...unhook the batteries and just take the valve cover off...you will then want to remove the black wiring harness that connects to the first two injectors and first two glow plugs. You will see two small plugs in the head...i think they are located between injectors 1 and 3 and 5 and 7. they are small and hard to see but they are positioned so that if you are standing at the side of the truck and look toward the valley of the engine and at the top of the valve train you can see them...they are a hex head plug...just remove the first one...between 1 and 3. this will release the oil rifle pressure. Next when looking at the injector itself you will see that it has three bolts holding it down...Two 8mm bolts and one hex bolt. Two of these bolts actually hold the injector down. You will need to remove the hex bolt...this is the hold down for the oil return ports...and remove the oil return port. Next remove the bottom most 8mm bolt completely and loosen the top 8mm bolt. Now take a prybar and carefully pry the injector out using the hold down bracket and a space on the head where you bolt the valve cover down...the injector o-ring kit has instructions for installing the o-rings. Clean out the injector bore well. Lube up the orings on the injector and insert it back into the bore. it takes a bit of force to fully seat the injector...do not use a hammer to seat them...you will break the injector solenoid. Reinstall all the bolts. Now take out that number one glow plug and set it aside where you wont loose it. Reinstall the hex plug that you removed earlier from the head. go around and unhook all the injector wiring harness connectors from the valve covers...there will be four total including the two that you just took off to remove the valve cover and gasket. This will keep the engine from starting. Now replace the valve cover gasket and cover...you only need to put four bolts in. Connect the batteries and Crank the engine for 2 seconds...this purges the cylinder of any oil that may have gotten down in there when you removed the injector. crank the engine again for 4 seconds. then again for another 4 seconds...do not just crank the engine for ten seconds...this puts a large strain on the batteries and starter. Now remove the valve cover and gasket and replace the glow plug you took out. Reinstall the black wiring harness and reinstall the valve cover and gasket tighten all the bolts and you are good to go.
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