Fuel Injectors - Early Build: Installation

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

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

Fig 1: Installing O-Ring Seals And Copper Washer On Fuel Injector

Courtesy of FORD MOTOR CO.

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.

CAUTION: To prevent engine damage, do not use air tools to install the fuel injectors. The clip that extracts the injector can dislodge and fall into the oil drain hole.

Fig 2: Installing Fuel Injector, Fuel Injector Hold-Down Clamp And Bolt With Torque Specifications

Courtesy of FORD MOTOR CO.

Install the fuel injector, fuel injector hold-down clamp and bolt.
Install the fuel injector electrical connector into the rocker carrier.

Fig 3: Installing Fuel Injector Electrical Connector Into Rocker Carrier
Courtesy of FORD MOTOR CO.
Apply engine oil to the top fuel injector O-ring seals.

Fig 4: Applying Engine Oil To Top Fuel Injector O-Ring Seals
Courtesy of FORD MOTOR CO.
Install the high-pressure oil rail and bolts.
- Install the high-pressure oil rail.
- Install the bolts finger tight.
  
  Fig 5: Installing High-Pressure Oil Rail And Bolts
  Courtesy of FORD MOTOR CO.
Tighten the bolts in the sequence shown.

Fig 6: High-Pressure Oil Rail Bolts Tightening Sequence With Torque Specifications
Courtesy of FORD MOTOR CO.
Install the high-pressure oil line.

Fig 7: Installing High-Pressure Oil Line
Courtesy of FORD MOTOR CO.
Connect the fuel injector electrical connector.

Fig 8: Connecting Fuel Injector Electrical Connector
Courtesy of FORD MOTOR CO.
Install the valve covers. Refer to ENGINE - 6.0L DIESEL .