Application: 1994 to 2002 Ford Diesel Powerstroke 7.3L.

Problem: Possible engine damage from oil and/or fuel entering the cylinder piston area.

Cause: Engine oil and fuel galleys run between the fuel injectors in the cylinder heads. When the injector is removed, oil and fuel can enter into the combustion chamber and collect on top of the piston. This will dilute the engine oil and can potentially cause major engine damage from hydraulic lock-up upon starting. The hydraulic lock-up can also cause damage to the starter, flywheel, cylinder heads and valve train components.

Solution: Drain all oil and fuel from cylinder heads prior to removal of the fuel injector. Remove the drain plugs under the valve covers and at the rear of the cylinder heads. Then remove the oil rail drain plugs located in the cylinder head between two of the push tubes. After the cylinder heads are drained, the fuel injectors can be removed and replaced with minimal oil and fuel drainage into the cylinders.

Caution: Serious engine damage can result if excessive amounts of fluids are allowed to drain into the engine cylinders.

Note: Refer to manufacturers service manual for repairs and specifications on these engines.

Tech Tip courtesy of CARDONE.

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