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How to Change Six Liter Power Stroke Injectors

The Power Stroke is a turbocharged diesel engine that Ford began making in 1994. The 6.0-liter version of this engine entered production in 2003, and it was the primary engine in Ford Super Duty trucks until 2008. The engine uses fuel injection to deliver specific amounts of fuel to each cylinder in a precise sequence. The fuel injectors in a 6.0-liter Power Stroke engine are part of the oil rail assembly, which you must remove to access the injectors.

Instructions

1

Disconnect the valve cover with a socket wrench. Unplug the electrical connector from the fuel injector.

2

Remove the crankcase-to-head tube assembly with a socket wrench. Disconnect the bolts that attach the oil rail to the engine and remove the oil rail. Extract the fuel injector electrical connector from the rocker arm carrier with a suitable pry tool.

3

Insert shop rags into the oil drain holes in the crankcase. Remove the bolt for the fuel injector with a socket wrench and disconnect the hold-down clamp from the fuel injector. Remove the fuel injectors from the oil rail assembly with a Snap-On SDMT440 Torx or similar tool. This is necessary to avoid damaging the plastic portion of the fuel injector. Pull the shop rags from the oil drain holes.

4

Mount new copper washers and O-rings to the new fuel injectors and coat the fuel injectors liberally with engine oil. Install the fuel injectors on the oil fuel rail and connect the hold-down clamps. Tighten the mounting bolt for the fuel injector to 24 foot-pounds, using a torque wrench.

5

Install the electrical connector for the fuel injector to the rocker arm carrier with a pry tool. Apply engine oil to the fuel injector to lubricate its top O-rings.

6

Mount the oil rail on top of its carrier. Insert a guide bolt on each end of the straight side of the oil rail, then insert a third guide bolt in the middle of the oil rails wavy side. Press the oil rail into position so that its mounting feet are flush against the oil rails mounting surface.

7

Install mounting bolts in the six remaining holes of the oil rail and replace the three guide bolts with mounting bolts. Tighten all of the mounting bolts to 10 foot-pounds, using a torque wrench.

8

Install the crankcase-to-head tube assembly. Tighten the bolts for the crankcase-to-head assembly to 60 foot-pounds, using a torque wrench. Plug the electrical connectors into the fuel injectors. Replace the valve cover with a socket wrench.

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