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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 730 (Fuel System & Engine Controls - 6.0L (99P E Series & F450/550) Diesel - Excursion & F250-F550 Super Duty) >> Removal And Installation >> Fuel Injectors - Late Build >> Installation

Fuel Injectors - Late Build: Installation

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    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.
    Fig 1: Installing O-Ring Seals On Each End Of Crankcase-To-Head Tube Assemblies
    G02773156Courtesy of FORD MOTOR CO.
  1. Install new O-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: Installing O-Ring Seals And Copper Washer On Fuel Injector
    G02773157Courtesy 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: 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: Installing Fuel Injector, Fuel Injector Hold-Down Clamp And Bolt With Torque Specifications
    G02773158Courtesy of FORD MOTOR CO.
  3. Install the fuel injector, fuel injector hold-down clamp and bolt.
  4. Install the fuel injector electrical connector into the rocker carrier.
    Fig 4: Installing Fuel Injector Electrical Connector Into Rocker Carrier
    G02773159Courtesy of FORD MOTOR CO.
  5. Apply engine oil to the top fuel injector O-ring seals.
    Fig 5: Applying Engine Oil To Top Fuel Injector O-Ring Seals
    G02773160Courtesy of FORD MOTOR CO.
    6. CAUTION: To prevent engine damage, check that 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 the tubes are not bottomed out.
    Fig 6: Applying Clean Engine Oil On Crankcase-To-Head Tube O-Ring Seals And Install Tubes
    G02773161Courtesy of FORD MOTOR CO.
  6. Apply clean engine oil on the crankcase-to-head tube O-ring seals and install the tubes.
    7. NOTE: Apply clean engine oil on the tubes prior to installing the oil manifold.
  7. 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 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 7: Installing Six Bolts
      G02773162Courtesy of FORD MOTOR CO.
  8. Install the oil rail retaining bolts.
    • Remove the three guide bolts.
    • Loosely install three remaining bolts.
    • Tighten the nine bolts in the sequence shown.
      Fig 8: Oil Rail Bolts Tightening Sequence With Torque Specifications
      G02773163Courtesy of FORD MOTOR CO.
  9. Connect the fuel injector electrical connector.
    Fig 9: Connecting Fuel Injector Electrical Connector
    G02773164Courtesy of FORD MOTOR CO.
  10. Install the valve covers. Refer to ENGINE - 6.0L DIESEL .
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