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Fuel Injectors: Installation

WARNING: This page is about a different car, the 2003 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Do not interchange fuel injectors. Incorrect injector installation can cause severe engine damage. Color of Service Parts identification clip may differ from color of Production identification clip. Verify identification using part number and parts catalog. Remove all oil and fuel from the cylinders before installing the fuel injectors. Failure to do so can cause hydrostatic lock, resulting in severe engine damage. Do not strike the top of the fuel injector to seat the injector in the cylinder head fuel injector bore. Damage to the fuel injector will occur. Use hand pressure on the top of the fuel injector until the fuel injector hold-down plate is flush with the cylinder head.
  1. Apply Threadlock 262 (E2FZ-19554-B) to injector sleeve. See Fig 1 . DO NOT apply threadlock to tapered areas. Install sleeve using Injector Sleeve Replacer and rubber mallet. See Fig 2 . Using the Injector Sleeve Brush Set, clean any residual sealant from sleeve and injector bore.
    2. NOTE: If required, install cylinder heads. See appropriate REMOVAL & INSTALLATION article.
  2. Inspect injector bore. Injector bore must be completely clean. If reusing fuel injector, replace "O" rings. See Fig 3 . Lubricate injector and "O" rings with engine oil. Install injector in head. Do not strike top of injector to install or seat injector. Using Injector Replacer, seat fuel injector. See Fig 4 . Install oil deflector and outer injector retaining bolt. Tighten bolts to specification. See TORQUE SPECIFICATIONS  .
  3. Install oil drain plugs and fuel drain plug located at the rear of each cylinder head. Tighten to specification. See TORQUE SPECIFICATIONS  .
  4. Install the electrical connector to valve cover gasket and position gasket in place. Connect electrical connector and install electrical connector retaining clip. Connect fuel injector connectors and secure fuel injectors attaching clips. Connect glow plugs electrical connectors.
  5. Install the valve cover.

    1. Left

      Install valve cover and 10 valve cover bolts. Tighten valve cover bolts to specification. See TORQUE SPECIFICATIONS  . Connect fuel injector/glow plug 9-pin connector and install retaining clip. Install oil fill tube.

    2. Right

      Install valve cover and 10 valve cover bolts. Install resonator bracket and nut. Tighten valve cover bolts and bracket nut specification. See TORQUE SPECIFICATIONS  . Connect fuel injector/glow plug 9-pin connector and install retaining clip. Install oil level indicator tube and nut.
  6. Raise and support vehicle. Raise engine until oil pan is off of crossmember. Install left engine mount and left engine mount-to-crossmember nuts. Lower engine and install left engine mount-to-engine bolts. Tighten right motor mount nuts. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS  .
  7. Lower vehicle. Connect A/C compressor wire. Install air cleaner, inlet duct and resonator. See AIR INTAKE RESONATOR  under AIR INDUCTION SYSTEMS. Connect negative battery cable. On vehicles with dual batteries, see DUAL BATTERIES  under MISCELLANEOUS.
Fig 1: Applying Threadlock To Injector Sleeve
G00011966Courtesy of FORD MOTOR CO.
Fig 2: Installing Fuel Injector Sleeve
G95G35861Courtesy of FORD MOTOR CO.
Fig 3: Installing New "O" Rings On Fuel Injector
G99A02481Courtesy of FORD MOTOR CO.
Fig 4: Installing Fuel Injector Using Injector Replacer
G95I35863Courtesy of FORD MOTOR CO.
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