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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 803 (Fuel Charging & Controls -- 6.0L Diesel (99P F450/550)) >> Removal And Installation >> Fuel Injectors >> Installation

Fuel Injectors: Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

    CAUTION: Install new D-ring seals on the crankcase-to-head tube. It requires several hours after installation for the D-ring seals to relax back to their original size. If the tube assembly is installed before the D-ring seals have relaxed, damage to the D-ring seals can occur.
    NOTE: Late build shown. Early build similar.
    Fig 1: Installing New D-Ring Seals
    G03899308Courtesy of FORD MOTOR CO.
  1. Install new D-ring seals on each end of the crankcase-to-head tube assemblies.
    2. CAUTION: If the fuel injector oil inlet D-shaped O-ring is damaged, a new fuel injector must be installed.
    Fig 2: Identifying Fuel Injector O Rings And Electrical Connector
    G03887397Courtesy of FORD MOTOR CO.
  2. Install new O-ring seals and copper washer on the fuel injector. Lubricate the fuel injector and O-ring seals liberally with clean engine oil.
    3. CAUTION: Failure to tighten the injector properly can lead to engine failure.
    CAUTION: To prevent engine damage, do not use air tools to install the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.
    Fig 3: View Of Fuel Injector Hold-Down Clamp Bolt - With Torque Specification
    G03887398Courtesy of FORD MOTOR CO.
  3. Install the fuel injector, fuel injector hold-down clamp and bolt.
    4. NOTE: If a snap ring or piece of a snap ring is missing from the injector hold-down assembly, it must be located prior to removing the shop towels.
  4. Remove the shop towels.
    5. CAUTION: Make sure the injector wiring is clear of all moving parts or engine damage can occur.
    Fig 4: Identifying Fuel Injector Electrical Connector At Rocker Carrier
    G03887399Courtesy of FORD MOTOR CO.
  5. Install the fuel injector electrical connector into the rocker carrier.
  6. Apply engine oil to the top fuel injector O-ring seals.
    Fig 5: Locating Top Fuel Injector O-Ring Seals
    G03888010Courtesy of FORD MOTOR CO.

    7. Early build vehicles 

    CAUTION: To prevent engine damage, check to make sure the crankcase-to-head tube assemblies bottom out in the branch tube assembly. The oil rail, crankcase-to-head tube and the fuel injectors will not function correctly if these tubes are not bottomed out.
    Fig 6: Identifying Crankcase-To-Head Tube
    G03887400Courtesy of FORD MOTOR CO.
  7. Apply clean engine oil on the crankcase-to-head tube D-ring seals and install the tubes.

    8. Late build vehicles 

    NOTE: Apply clean engine oil to the D-ring seal, prior to installing.
    Fig 7: Positioning Lower Section Of Crankcase-To-Head Tube In Engine
    G03888012Courtesy of FORD MOTOR CO.
  8. Position the lower section of the crankcase-to-head tube in the engine.

    9. All vehicles 

    NOTE: Apply clean engine oil on the tubes prior to installing the high-pressure oil rail.
  9. Position the oil rail on the fuel injectors.
    • Place the oil rail on top of the carrier so that the four single ball tubes are engaging the injector lead angle.
    • Insert three guide bolts, two on the ends of the straight side of the oil rail and one in the middle of the wavy side of the rail. Install the guide studs six to seven turns.
    • Press the oil rail into the fuel injectors.
    • Make sure that the oil rail mounting feet are flat against the mounting surface.
    • Loosely install the six bolts.
      Fig 8: Locating High-Pressure Oil Rail On Injector Bolts
      G03887401Courtesy of FORD MOTOR CO.
  10. Install the oil rail retaining bolts.
    • Remove the three guide bolts.
    • Loosely install three remaining bolts.
    • Tighten the nine bolts in the sequence shown in Fig 9.
      Fig 9: Oil Rail Retaining Bolt Tightening Sequence - With Torque Specifications
      G03887402Courtesy of FORD MOTOR CO.

    11. Late build vehicles 

    NOTE: The upper section will have to be pushed into the lower section prior to the threads engaging.
    NOTE: Apply clean engine oil on the D-ring seals, prior to installing.
    Fig 10: Crankcase-To-Head Tube Bolt With Torque Specification
    G03887403Courtesy of FORD MOTOR CO.
  11. Install the upper section of the crankcase-to-head tube.

    12. All vehicles 

  12. Connect the fuel injector electrical connector.
    Fig 11: Identifying Fuel Injector Electrical Connector & Retainer Clip
    G03887113Courtesy of FORD MOTOR CO.
  13. Install the valve covers. For additional information, refer to ENGINE - 6.0L DIESEL .
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