7.3 Powerstroke Injector Installation Suggestions

Pressurized fuel lines feed fuel to the injectors on Ford's 7.3liter Powerstroke diesel engine. O-rings connect the fuel injectors to the fuel lines and engine. The fuel injector electrical plug provides an electrical current to the injector to charge a solenoid, which opens a valve to allow the fuel to pass through the injector nozzle.

O-Ring Replacement

Always replace O-rings if you remove the injector from the fuel rail or engine. Microscopic damage to the O-rings may occur during installation and removal. Leaks in the O-rings resulting from small cracks create fire hazards in the engine compartment.

O-Ring Lubrication

Coat new O-rings with clean motor oil to lubricate the installation process and help protect the material from degrading over time. Substitute oil with petroleum jelly if you prefer a more viscous material. Injector O-ring material is designed to work with petroleum products.

Dielectric Grease

Coat the fuel injector terminal posts with pure silicone dielectric grease. The grease will provide a coating over the metal to prevent corrosion and electrical shorting. Coat the electrical plugs that connect to the injector terminals if they are more accessible.

Injector Cleaning

Periodically clean the injectors with injector cleaner to prevent buildup of fuel gums, varnishes and deposits. Clean injectors atomize fuel more efficiently for better combustion.

Replace Worn Injectors

Injectors have moving parts that wear out. Poorly performing injectors that do not respond to periodic cleaning may have worn-out valves. Replace worn injectors for improved performance and power.

Hand Installation

Use your hands to install the injectors in the engine. Tool damage to the injectors, O-rings and O-ring seats may result in fuel leaks.

Testing O-ring Seating

Pull the injector upward slightly once the injector is seated in the engine. Properly seated injectors will resist removal. If you can extract the injector easily, check the O-ring seating to ensure it is fully in position.

Oil Spout Removal

Remove the oil spouts before removing the injectors. Early removal prevents damage to the oil spouts and allows you to use them on replacement injectors.

Copper Washer

Take care not to knock the copper washer from the tip of the injector during removal. If the washer becomes dislodged, you must remove it from the engine head before starting the engine. Failure to remove the metal part from the engine head will result in engine damage.