Fuel Injector: Service and Repair

REMOVAL

WARNING
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

1. Disconnect the battery ground cable.
2. Relieve the fuel pressure.
3. Disconnect the fuel lines.
4. Remove the throttle body.
5. On gasoline engines, remove the EGR valve to exhaust manifold tube.
6. Remove the drive belt.







7. Disconnect the fuel temperature sensor connector.







8. Disconnect the fuel pressure sensor connector.







9. Disconnect the connector.
10. Disconnect the main fuel shut-off solenoid connector.







11. Remove the bolts and the generator mounting bracket.







12. Remove the bolts.







13. Unclip the accelerator cable and the speed control actuator cable from the two crash brackets and position out of the way.







14. Separate the LH heated oxygen sensor and the transmission electrical connector from the bracket at the rear of the cylinder head.







15. Remove the nut-bolt and the wiring bracket







16. Disconnect the vacuum lines and position out of the way.

NOTE: On natural gas vehicles, there are no EGR vacuum connections.







17. Disconnect the eight fuel injector electrical connectors.







18. Disconnect the crankcase ventilation tube and position out of the way.







19. On gasoline engines, disconnect the vacuum line.







20. On gasoline engines, disconnect the vacuum line from the Evaporative Emission (EVAP) canister purge valve.







21. On gasoline engines, disconnect the EGR vacuum regulator solenoid.
22. Remove the bolt and the stud.
23. Remove the crash bracket.
24. Remove the studs.
25. Remove the fuel injection supply manifold and the fuel injectors as an assembly.

INSTALLATION
1. Lubricate the fuel injector pockets with clean engine oil XO-10W30-QSP or DSP or equivalent meeting Ford specification WSS-MZC153-G, to aid installation.

CAUTION: Use O-rings that are made of special fuel resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse O-rings.

NOTE: Natural gas fuel injectors are identified by an aqua cap.

2. Install the fuel injection supply manifold and the fuel injectors as an assembly
3. Torque fuel injection supply manifold bolts to specification.
4. Install the studs.
5. Install the crash bracket.
6. Install the bolt and the stud.







7. On gasoline engines, connect the EGR vacuum regulator solenoid.







8. On gasoline engines, connect the vacuum line to the evaporative emission canister purge valve.







9. On gasoline engines, connect the vacuum line.







10. Connect the crankcase ventilation tube.







11. Connect the eight fuel injector electrical connectors.







12. Connect the vacuum lines.

NOTE: On natural gas engines there are no EGR vacuum connections.







13. Install the fuel supply retaining bracket nut and bolt.







14. Attach the LH heated oxygen sensor connector and the transmission electrical connector to the bracket at the rear of the cylinder.







15. Clip the accelerator cable and the speed control actuator cable to the two crash brackets.







16. Install the bolts.







17. Install the generator mounting bracket and tighten the bolts.
18. Connect the main fuel shut-off solenoid connector.







19. Connect the connector.







20. Connect the fuel pressure sensor connector.







21. Connect the fuel temperature sensor connector.
22. Install the drive belt.
23. On gasoline engines, install the EGR valve to exhaust manifold tube.
24. Install the throttle body.
25. Connect the fuel lines.
26. Connect the battery ground cable.