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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1926 (Fuel Charging And Controls - 6.0L Diesel - F250-F550) >> Removal And Installation >> Fuel Injectors >> Installation

Fuel Injectors: Installation

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    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.
  1. Install new D-ring seals on the crankcase-to-head tube assemblies.
    2. Fig 1: Identifying D-Ring Seals
    G03899308Courtesy of FORD MOTOR CO.
    CAUTION: If the fuel injector oil inlet D-shaped O-ring is damaged, a new fuel injector must be installed.
  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. Fig 2: Identifying O-Ring Seals, Copper Washer And Fuel Injector
    G03887397Courtesy of FORD MOTOR CO.
    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.
  3. Install the fuel injector, fuel injector hold-down clamp and bolt.
    • Tighten to 35 Nm (26 lb-ft).
    4. Fig 3: Identifying Fuel Injector Hold-Down Bolt
    G03887381Courtesy of FORD MOTOR CO.
    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.
  5. Install the fuel injector electrical connector into the rocker carrier.
    6. Fig 4: Identifying Fuel Injector Electrical Connector
    G03887399Courtesy of FORD MOTOR CO.
  6. Apply engine oil to the top fuel injector O-ring seals.
    7. Fig 5: Identifying Top Fuel Injector O-Ring Seals
    G03888010Courtesy of FORD MOTOR CO.
    CAUTION: Using the bolts to push the high pressure oil rail into the fuel injectors can damage the fuel injectors and high pressure oil rail.
    NOTE: Apply clean engine oil on the tubes prior to installing the high pressure oil rail.
  7. Position the oil rail on the fuel injectors.
    • Place the oil rail on top of the carrier so that the 4 single ball tubes are engaging the injector lead angle.
    • Insert 3 guide bolts, 2 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 6 to 7 turns.
    • Manually 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 6 bolts.
    8. Fig 6: Locating High-Pressure Oil Rail On Injector Bolts
    G03887401Courtesy of FORD MOTOR CO.
  8. Install the oil rail retaining bolts.
    • Remove the 3 guide bolts.
    • Loosely install 3 remaining bolts.
    • Tighten the 9 bolts in the sequence shown.
    • Tighten to 13 Nm (10 lb-ft).
    9. Fig 7: Identifying High-Pressure Oil Rail Bolt Tightening Sequence
    GF0005913Courtesy of FORD MOTOR CO.
  9. Apply clean engine oil and install the crankcase-to-head tube.
    • Tighten to 82 Nm (60 lb-ft).
    10. Fig 8: Locating Crankcase-To-Head Tube
    GF0005912Courtesy of FORD MOTOR CO.
  10. Connect the fuel injector electrical connector.
    11. Fig 9: Identifying Fuel Injector Electrical Connector & Retainer Clip
    G03887113Courtesy of FORD MOTOR CO.
  11. Install the valve covers. For additional information, refer to ENGINE - 6.0L DIESEL article.
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