Replacing the Powerstroke injectors on your Ford’s 7.3-liter engine is a piece of cake. Sure, you could pay someone to do the job for you, but you’ll end up saving plenty of money if you do the job yourself.
Torque wrench with inch-pound measurement
Small pry bar
13 mm, 11 mm and 8 mm sockets
Deep 10mm socket
5 mm Allen wrench
24mm socket with breaker bar
Removing the Injector
Using the 10 mm socket, start by removing the plastic engine cover. Next, remove the air filter assembly, turbo intake hose and the closed crankcase ventilation assembly. Disconnect the intercooler tubes and disconnect the main wiring harness.
Move to the driver’s side and remove the 13 mm bolts holding the valve cover and remove the valve cover itself. Next, locate the metal clips holding the injectors in place and flip them down. Afterwards, gently disconnect the injectors and the glow plugs. Carefully remove the valve cover gasket and set it aside for reuse.
Disconnect the oil spouts with a 5 mm Allen wrench and set them aside. Remove the lower injector retaining bolt using the 8 mm socket. Removing the upper bolt is unnecessary, as the injector’s mounting collar will slide off the upper bolt.
Disconnect the injectors starting with the rearmost injector first. Use the small pry bar to carefully lift the injector out of its seat. Use shop towels to clean up excess oil and fuel. Afterwards, use the 10 mm socket to remove the glow plugs.
Installing the Injector
Coat the new injector in clean engine oil and place it in its seat. Moderately tap the injector into the seat with the rubber mallet until the mounting collar slides over the upper retaining bolt.
Secure the injector with the lower retaining bolt. Use the torque wrench with the 8 mm socket to tighten the bolt to 120 inch-pounds. Reattach the oil spouts and tighten the 5 mm Allen bolt. Replace the valve cover gasket and secure the injector via the metal clip. Retain but do not tighten the valve cover with the 13 mm bolts.
With the glow plugs disconnected, purge the excess fuel and oil out of the cylinders by cranking the vehicle for 20 seconds. Allow the starter to cool down and crank for another 20 seconds. Reinstall the glow plugs by torqueing each plug with the 10 mm socket to 168 inch-pounds and reattach the glow plug connectors.
Torque the valve covers to 96 inch-pounds with the torque wrench and 13 mm socket. Reinstall all of the plumbing removed in the first step and reconnect all harnesses save for the valve cover harness. Crank the engine for 20 to 30 seconds to rebuild oil pressure, and then plug the valve cover harness back in.