7.3 Powerstroke Injector Replacement Cost

The 7.3 Powerstroke diesel engine was produced by Ford from 1994-2003 and was popular for its power and reliability. However, one common issue owners of these trucks face is failing injectors.

Today, we'll explain what causes 7.3 Powerstroke injectors to fail, the symptoms of a failing injector, and provide an estimate for the cost to replace the injectors.

Why Do 7.3 Powerstroke Injectors Fail?

There are a few main reasons why 7.3 Powerstroke injectors tend to fail over time:

• Normal wear and tear - Like any other component in a vehicle, diesel injectors are subjected to heat, pressure, and friction each time the engine is started. Over many years and hundreds of thousands of miles, this normal operation causes injectors to gradually degrade.
• Carbon buildup - As diesel fuel is injected into the combustion chamber, carbon deposits form inside the injector. Over time, this carbon buildup can prevent the injector from functioning properly.
• Contaminated fuel - Dirt, moisture, or other contaminants in the fuel can damage delicate injector parts or clog fuel filters and lines leading to the injectors.
• Incorrect diagnosis/repair - If a previous shop misdiagnosed an injector issue or performed an incomplete repair, it can cause remaining injectors to fail prematurely down the road.

The combination of heat, pressure, carbon buildup, and other factors ultimately takes its toll on injectors after 10-15 years or 200,000+ miles of use in most cases. Replacing them is usually needed to restore proper engine performance.

Symptoms of a Failing 7.3 Powerstroke Injector

Here are some common symptoms that indicate one or more 7.3 Powerstroke injectors may be failing:

• Rough idle - The engine will feel rough or shaky at idle and may idle high.
• Hesitation/lag on acceleration - When pressing the gas, the engine feels sluggish to respond.
• Loss of power - Overall power and torque are reduced, especially at higher RPMs.
• Black or gray smoke from exhaust - A failing or stuck open injector allows too much fuel into the cylinder.
• High exhaust gas temperature (EGT) - An inefficient combustion causes exhaust gas temps to rise above normal levels.
• Check engine light - The PCM senses abnormalities and turns on the CEL.
• Diagnostic trouble codes (DTCs) - Codes related to individual injectors like P12XX will be stored.

The symptoms tend to worsen over time as the faulty injector degrades further. Having the diagnostic trouble codes read with a scan tool can help pinpoint which specific injector needs to be replaced.

7.3 Powerstroke Injector Replacement Cost Estimate

The average cost to replace all the injectors in a 7.3 Powerstroke engine ranges from $1,500 to $2,500 depending on factors like:

• Labor rates in your area - Labor typically accounts for half or more of the total cost.
• Number of cylinders replaced - Replacing all 8 injectors vs. just a few bad ones.
• Brand of replacement injectors - OEM vs. aftermarket rebuilt or remanufactured injectors.
• Additional needed services - Carbon cleaning or other work that may be recommended.

Here's a breakdown of injector replacement costs to help give you an idea of what to budget:

Single Injector Replacement

• Injector part cost: $100-200 each
• Labor cost: 1-2 hours at $100-150/hour
• Total for 1 injector: $200-400

All 8 Injectors Replacement

• Injector part cost: $800-1600 (8 x $100-200 each)
• Labor cost: 8-12 hours at $100-150/hour
• Total for full set: $1500-2500

You may also see additional costs if the injector sleeves need to be replaced or other repairs are required as part of the overall job. Reputable diesel shops typically use factory OEM or top-quality remanufactured injectors for best reliability.

Can Injectors Be Rebuilt?

In some cases, it may be possible to have failing 7.3 Powerstroke injectors rebuilt rather than replacing them. The process involves having a shop disassemble the injector, clean all parts, replace worn seals and O-rings, lap seal surfaces, test and calibrate fuel pressures.

The cost for a rebuild is usually half that of new replacement injectors. However, injectors with significant carbon buildup or physical damage inside may not be rebuildable. Rebuilding also doesn't address the root causes like contaminated fuel that lead to premature injector failure down the road. So replacement is often recommended if symptoms have persisted for a long time.

If you opt to rebuild rather than replace, look for a shop with experience rebuilding 7.3 Powerstroke injectors. Proper rebuilding requires specialized tools, calibration equipment, and technical know-how to fully restore injector performance.

Tips For Replacing 7.3 Powerstroke Injectors Yourself

It's possible for a DIY mechanic to replace the injectors, but it requires some specialized tools and skills. Here are some tips if you plan to do the work yourself:

1. Obtain a repair manual such as a Chilton or Haynes manual to guide you through the process step-by-step.
2. Invest in a good torque wrench capable of clicking at the proper injection torques. Over or under torque can damage components.
3. Purchase a diagnostic scan tool so you can retrieve and clear any stored DTC trouble codes related to injectors.
4. Watch instructional YouTube videos made by other DIY mechanics to see the job done visually.
5. Prepare by having all gaskets, o-rings, and seals on hand prior to removing old injectors.
6. Thoroughly clean the area around each injector and associated fuel lines before replacement.
7. Apply a small amount of fresh engine oil to o-rings when installing new injectors to aid sealing.

Be sure to clear any codes, start the engine, and monitor for leaks after installation. Have a friend observe for smoke on initial start up as well. Injector replacement requires care and precision to avoid further issues.

Alternatives To Replacing 7.3 Powerstroke Injectors

If the cost of injector replacement is more than you want to spend, here are a few lower-cost alternatives to consider:

• Fuel additive - Products containing Cetane boost and cleaning agents can sometimes temporarily improve performance of failing injectors.
• Injector cleaning - Some technicians offer an in-cylinder injector cleaning service where spray bars are used to blast carbon deposits from injectors. This buys some time but deposits build back up quickly.
• Reduce unnecessary load - Avoid towing heavy loads, carrying excess weight in the truck, or other stress on the engine until injectors can be addressed.
• Consider trading in - The repair costs may exceed the vehicle's current value. Research trade-in options versus investing further funds in older high-mileage trucks.

However, ultimately injectors that have failed or are near end-of-life typically need replacement to fully restore engine performance and efficiency. Catching issues sooner prevents further damage down the road as well.

Should You Replace 7.3 Powerstroke Injectors Yourself?

Replacing the injectors is a complex job with risk for additional problems if not done properly:

Pros of keeping a 7.3 Powerstroke with injector replacement:

• Diesels are designed to last hundreds of thousands of miles and these engines can run strong with proper maintenance.
• Parts and systems other than injectors may have many years of life remaining.
• You avoid the risks and costs of a new vehicle like depreciation and unexpected repairs.
• Mechanically-minded owners enjoy wrenching on and maintaining their trucks.

Cons of DIY replacement:

• Special tools required can increase costs.
• Risk of damage from improper installation techniques.
• Difficulty diagnosing and repairing any new issues that arise.
• More time consuming than having professionals handle it.
• Warranty coverage may be voided for future injector problems.

Unless you have extensive experience wrenching on diesel engines, it's usually best to let a trained mechanic handle the injector replacement. They have the specialized tools, equipment for proper torqueing, and expertise required to do the job right the first time.

That helps avoid potential further expenses down the line from mistakes made during a DIY replacement. For most drivers, the added cost of professional installation is worth avoiding unnecessary headaches later on.

Maintenance To Prolong Injector Life

While injectors will eventually need to be replaced, there are some maintenance practices you can adopt to maximize their service life:

• Use high-quality diesel fuel without contamination or additives.
• Change the fuel filters regularly as directed in the owner's manual.
• Install and maintain a fuel water separator filter on the supply line.
• Avoid long periods of low-rpm idling which causes excessive heat buildup.
• Inspect and replace worn drive belts that power engine accessories.
• Check for any air or vacuum leaks that upset the fuel regulation system.
• Load test the batteries - weak batteries can cause injector-damaging voltage drops.
• Consider occasional fuel additive treatments containing cleaning agents.

Consistent, on-schedule service helps the 7.3 Powerstroke run at peak efficiency for as long as possible before major repairs become necessary.

Should You Keep Or Replace Your 7.3 Powerstroke?

When injectors eventually start to fail, owners wrestle with whether to put more money into repairs or consider replacing the truck. Factors to weigh include:

• Age and mileage - Older high-mileage trucks may not be worth further investment.
• Maintenance history - Regularly serviced vehicles tend to last longer than neglected ones.
• Condition of other components - Replacing expensive injection pumps or turbos may not make sense.
• Cost of repairs vs. truck value - Costs should not exceed the current fair private party value.
• Desired years of remaining use - Plan for recurring injector replacements down the line.

With repairs approached wisely, many 7.3 Powerstrokes with a clean history can provide several more years of useful service. Ultimately the numbers need to make sense when weighing repair costs versus upgrading to a newer truck.