Fuel Injectors: Installation

WARNING: This page is about a different car, the 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: 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.

Install new D-ring seals on each end of the crankcase-to-head tube assemblies.

Fig 1: Identifying D-Ring Seals

Courtesy of FORD MOTOR CO.

NOTE: If the fuel injector oil inlet D-ring is damaged, a new fuel injector must be installed.

NOTE: Lubricate the fuel injector and O-ring seals liberally with clean engine oil.

Install new O-ring seals and a copper washer on the fuel injector.

Fig 2: Identifying O-Ring Seals, Copper Washer And Fuel Injector

Courtesy of FORD MOTOR CO.

NOTE: Failure to tighten the injector correctly can lead to engine failure.

NOTE: To prevent engine damage, do not use air tools to remove or install the fuel injectors.

Install the fuel injector, the fuel injector hold down and bolt.
- Tighten to 35 Nm (26 lb-ft).

Fig 3: Identifying Fuel Injector Hold-Down Bolt

Courtesy of FORD MOTOR CO.

Remove the shop towels.

NOTE: Make sure the injector wiring is clear of all moving parts or engine damage can occur.

Install the fuel injector electrical connector into the rocker carrier.

Fig 4: Identifying Fuel Injector Electrical Connector

Courtesy of FORD MOTOR CO.

Apply clean engine oil to the top fuel injector O-ring seals.

Fig 5: Identifying Top Fuel Injector O-Ring Seals

Courtesy of FORD MOTOR CO.

NOTE: Apply clean engine oil to the D-ring seal, prior to installing.

Position the lower section of the crankcase-to-head tube in the engine.

Fig 6: Crankcase-To-Head Tube

Courtesy of FORD MOTOR CO.

NOTE: 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 to the top fuel injector D-ring seals before installing the high-pressure oil rail.

Position the high-pressure oil rail on the injectors.
- Place the high-pressure oil rail on top of the carrier so that the 4 single ball tubes are engaging the fuel injector lead angle.
- Insert 3 guide bolts, 2 on the ends of the straight side of the high-pressure oil rail and 1 in the middle of the wavy side of the high-pressure rail. Install the guide studs 6 to 7 turns.
- Manually press the high-pressure oil rail into the fuel injectors.
- Inspect that the high-pressure oil rail mounting feet are flat against the mounting surface.
- Loosely install the 6 high-pressure oil rail bolts.

Fig 7: Identifying Bolts And High-Pressure Oil Rail

Courtesy of FORD MOTOR CO.

Remove the 3 guide bolts, install the remaining high-pressure oil rail bolts and tighten the 9 bolts in the sequence shown.
- Tighten to 13 Nm (115 lb-in).

Fig 8: High-Pressure Oil Rail Bolt Tightening Sequence

Courtesy of FORD MOTOR CO.

Apply clean engine oil and reassemble the crankcase-to-head tube. Install the crankcase-to-head tube.
- Tighten to 82 Nm (60 lb-ft).

Fig 9: Locating D-Ring Seals

Courtesy of FORD MOTOR CO.

Connect the fuel injector electrical connector.

Fig 10: Identifying Fuel Injector Electrical Connector & Retainer Clip

Courtesy of FORD MOTOR CO.

Install the valve covers. For additional information, refer to ENGINE - 6.0L DIESEL article.