This is an attempt at a step by step guide only to changing out the injector seals on a 2007 PJ Ford

Ranger 3.0 TDCI diesel engine.

Sorry no pictures

This does not include any calibration or programming work if the injectors are replaced.

1. Disconnect the battery

2. Remove 2 dome nuts that hold the top engine cover in place (10mm socket)

3. Remove the top engine cover. This should now just pull off the rear stops

4. Undo the 4 bolts that hold the injector harness to the rocker cover (1 of these bolts is a pin for the
engine cover) 10mm & 12mm ring spanner

5. Unplug each injector from the harness (fold back the bracket and the harness so it’s out of the
way)

6. Remove the 4 clips that hold the fuel return line to each injector (flat end screw driver does the
trick here)

7. Pull each fuel line out of the top of each injector gently and place out of the way (be sure to keep
any contamination out of the top of the injector return lines and injectors)

8. Undo the nuts that hold the injector fuel lines to the rocker cover (8mm ring spanner)

9. Undo each injector fuel line and mark 1 to 4 in order (17mm open end spanner or split ring
spanner if you have one)

10. You should now be able to reach the clamps that hold the injectors in place

11. Mark each injector 1 to 4 (so they all go back in the rite order)

12. Undo each clamp bolt until it can be pulled out but do not pull it out

13. This is the trick

14. Remove the clamp bolt from 1 only injector clamp and wriggle the injector while pulling up until
it starts to come free but do not pull it out of its hole
15. Drop the clamp bolt back in to its hole and as you pull the injector up and out pull the clamp and
bolt with it (they should come out all as a unit)

16. Place a screwdriver in the injector hole and remove the steel/rubber washer that was under the
clamp (the screw driver will stop you accidentally dropping the washer down the hole)

17. Repeat steps 13 to 15 for each injector

18. With a piece of wire or a screw driver reach down in the injector ports and remove the copper
washer that is down inside at the bottom (sometimes it will come out with the injector but not
always)

19. Check the injector ports and the seat at the bottom and remove any contamination (do not
damage the seat at the bottom

20. Check each injector and remove any carbon/contamination very carefully (do not damage the
bottom end of the injector as this is quite delicate - $1000.00 ea if you do damage one)

21. Take a long screw driver and slide 1 new copper washer/seal over it and hold it under the handle
(new copper washers are about $2.50 ea from Ford Genuine Parts)

22. Slide the screw driver down the injector port and let the washer go (just a little trick) the washer
should be seated in place

23. Take the first injector complete with clamp, steel/rubber washer and bolt assembly and slip in to
place in the injector port making sure the injector is seated all the way in

24. Screw the clamp bolt down finger tight only

25. Repeat steps 21 to 24 for each injector

26. Take a torque wrench and tension down each clamp bolt to between 21 – 26 ft-lbs (this ensures
the correct pressure on the copper washer/seal not to leak)

27. Install the injector fuel lines in correct order, install the 4 pipe brackets and tighten all nuts
(manual s suggests that the injector lines only be re-used 6 time then be replaced)

28. Install the 4 clips that hold the return fuel lines in place

29. Fit the return fuel line by placing the fitting over the injector and press firmly in to place (you
should hear a click)
30. Re install the injector harness bracket in place and connect the harness to the injectors in the
correct order

31. Connect up the battery

32. Prime the fuel system and turn the engine over until it fires and runs smooth

33. Check all fuel connections and fuel lines for fuel leaks

34. Use some soapy water and spray around the base of each injector and check for any bubbles (if
there are bubbles the copper washer has not sealed correctly – check clamp bolt torque, injector
seat damage or contamination)

35. Run up to normal working temperature and re check for leaks with soapy water

36. Test drive and re check for any leaks

37. If all is well, stop engine and replace the engine cover