Fuel Injectors: Installation

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Verify that the fuel injector-to-valve cover seal is squarely seated in the valve cover.

Using a 22 mm (0.866 in) socket or equivalent, install the new fuel injector-to-valve cover seal.

Fig 1: Locating Fuel Injector-To-Valve Cover Seal
Courtesy of FORD MOTOR CO.
Install a new fuel injector body O-ring seal and a new copper combustion gasket onto the fuel injector.
- Install a new fuel injector return fuel O-ring.
NOTE: If a fuel injector is being reused, make sure to install it in the original location.

Install the fuel injector, the fuel injector hold-down clamp and a new fuel injector hold-down clamp bolt.
1. Lubricate the fuel injector hold-down clamp bolt mating surface of the fuel injector hold-down clamp with clean engine oil.
2. Tighten the fuel injector hold-down clamp bolt to 30 Nm (22 lb-ft).
3. Tighten the fuel injector hold-down clamp bolt an additional 90°.
NOTE: If more than one fuel injector supply tube has been removed from either cylinder head, the 2 fuel rail mounting bolts must be loosened before the new fuel injector supply tubes are installed.

If necessary, loosen the 2 fuel rail mounting bolts.
NOTE: Use a deep-well crowfoot socket to tighten the fuel injector supply tube.

Install the new fuel injector supply tube in the following sequence.
1. Position the new fuel injector supply tube between the fuel rail and the fuel injector. Fully hand-start and seat the fuel injector supply tube fittings onto the fuel rail and the fuel injector high-pressure connectors.
2. If necessary, tighten the 2 fuel rail mounting bolts.
  - Tighten to 24 Nm (18 lb-ft).
3. Pre-tighten the fuel injector supply tube fittings.
  - Tighten the fuel injector fitting to 20 Nm (177 lb-in).
  - Tighten the fuel rail fitting to 20 Nm (177 lb-in).
4. Final-tighten the fuel injector supply tube fittings.
  - Tighten the fuel injector fitting to 35 Nm (26 lb-ft).
  - Tighten the fuel rail fitting to 35 Nm (26 lb-ft).
If necessary, connect the fuel pressure control valve electrical connector.
Connect the fuel injector return hose fitting to the fuel injector.
- Push down on the center of the fuel injector return hose fitting to lock the fitting.
  
  Fig 2: Pushing Down Fuel Injector Return Hose Center Fitting
  Courtesy of FORD MOTOR CO.
Connect the 3 fuel injector wiring harness retainers to the fuel rail.
Connect the fuel injector electrical connector.
Position the RH or LH engine sound shield and install the 5 RH or LH engine sound shield retainers.
If necessary, install the glow plug module. For additional information, refer to GLOW PLUG SYSTEM - 6.7L DIESEL .
Install the RH or LH fender splash shield. For additional information, refer to FRONT END BODY PANELS .
Connect the battery ground cable(s). For additional information, refer to BATTERY, MOUNTING AND CABLES .
NOTE: A fuel injector replacement label must be installed for each fuel injector that was replaced.

Install the fuel injector replacement label to the top of the oil separator housing and circle the cylinder number for the fuel injector that has been replaced.
NOTE: The PCM must be programmed with the proper fuel injector IQA codes.

Using the scan tool, program the PCM with the appropriate fuel injector IQA code for any fuel injector that was replaced. For additional information, refer to the INTRODUCTION - DIESEL MODELS .
Prime the fuel system by cycling the ignition 3 times as follows:
1. Turn the ignition key ON without cranking the engine.
2. Wait 30 seconds for the fuel conditioning module to run.
3. Turn the ignition key OFF.