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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 202 (Engine Controls - Removal & Installation - 7.3L 995 & 99F F450/550 Diesel) >> Fuel System >> Fuel Injectors >> Installation

Fuel Injectors: Installation

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. 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 article in ENGINES.
  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 air cleaner outlet tube. Install charge air cooler, turbocharger intake tube and bracket assembly. See CHARGE AIR COOLER  and TURBOCHARGER INTAKE TUBE  under AIR INDUCTION SYSTEMS.

    2. Right

      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. Position oil level indicator tube and install nut. Connect wiring harness as necessary. Install heater hose stand-offs and connect heater hoses. Install charge air cooler inlet tube. Connect MAP sensor electrical connector.
  6. 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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