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Articles .: Ford Excursion & Super Duty (F250/F350/F450/F550) .: Diesel Engine, Intake, & Exhaust .: Replacing Injectors On 1999-2003 7.3L Power Stroke Diesels

Replacing Injectors On 1999-2003 7.3L Power Stroke Diesels


Loosen plug on back of head to drain fuel. Remove intercooler tube and valve cover. Unplug injector and remove oil deflector on top side 8mm bolt.

Remove 8mm bolt on lower side. pry up on injector to remove. Oil will drain into cylinder. I use a vacuum evac system to suction the oil out. You can stuff a rag in and absorb as much as possible. Crank engine with ratchet at least two revolutions and absorb as much as possible.

Unplug UVC harness both sides and remove fuel pump fuse. Crank engine with starter to blow out the rest. Bump the starter slowly at first so you don't hydraulic a cylinder. Oil o-rings and install injector. Bump it with the palm of your hand to seat it. Tighten injector to 10 ft lbs. Remove oil drain plug in cylinder head. There are two in each head, under valve cover between injectors. Should be 1/8 allen wrench size. Tighten fuel drain plug.

Fill hpop with clean oil. Crank the engine until oil is pumped out this plug. Reassemble as removed. The engine will crank for a while until the hpop builds pressure and will run rough for a while.

Helpful Tips From Another User For This Procedure

Don't mess with the plug on the back of the head unless you want to. There is some fuel in the rails but it can be dealt with pretty easily.

First pump the oil out of the high pressure oil pump reservoir. It's about a quart or so. The plug on the top can be removed for the Mity Vac to gain access.

You do need to remove the plug that is on the head that leads to the high pressure oil rail. It is drilled in-line with one of the injectors and faces the lifter valley. You will want to use the Mity Vac to suck out all the oil in the head, it will be another quart or so.

Get three rags or paper towels. Have them ready to go, sitting right there next to you. The second you pull the injector, stuff a rag into the hole. Wait 5 seconds. Pull that rag out and stuff another one in there. Wait 5 seconds. Pull it out and stuff the third one in there. Leave it there for now. Between pumping the oil you can out of the rail and the rags soaking it up, you will have captured about 90% of the fuel and oil that would have drained into the cyl.

Mity-vac what you can out of the cyl and also pull the glow plug and turn the motor over by hand a few times with a breaker bar. A nice little mist will spray up and out letting you know it's ok to put the glow plug back in. It is an excellent time to put in new glow plugs.

Before you put the injector back in, spray a little brake cleaner down the hole. It will blow any tiny bits of build-up down into the cylinder so the copper gasket on the new injector can get a good seal.

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