Fuel Injector Re-installment
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Fuel Injector Re-installment
I'm in the process of putting my intake back together. I can't get my injectors back in. Is there some trick to it? Should I tap them in with a hammer and piece of wood? Someone please help, I need the truck back on the road. Thanks.
Fleet Owner
Joined: Aug 2005
Posts: 23,667
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From: Easton,Ks
Here is what the books says on doing it:
1. Lubricate new O-rings with light 10W-30 oil WSE-M2C903-A2 or equivalent and install two on each injector.
CAUTION:
Never use silicone grease. It will clog the injectors.
2. Install injector(s) using light, twisting, pushing motion.
3. Install «fuel supply manifold» as outlined in this section.
4. Install electrical harness connectors to injectors.
5. Install upper intake manifold as outlined in this section. Perform Steps 1 through 5 of Fuel Charging Assembly, Post-Service Procedures.
1. Lubricate new O-rings with light 10W-30 oil WSE-M2C903-A2 or equivalent and install two on each injector.
CAUTION:
Never use silicone grease. It will clog the injectors.
2. Install injector(s) using light, twisting, pushing motion.
3. Install «fuel supply manifold» as outlined in this section.
4. Install electrical harness connectors to injectors.
5. Install upper intake manifold as outlined in this section. Perform Steps 1 through 5 of Fuel Charging Assembly, Post-Service Procedures.
Cargo Master
Joined: Jul 2009
Posts: 2,541
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From: Des Moines
Are you sure you're not trying to force them in further than they're supposed to go? They only fit inside the larger bore- the smaller bore is simply a guide for the tip. If they feel like they're a little bit loose, it's okay- that's just how it goes together. I tried forcing my injector thru the smaller bore because that's where I thought it should go and I ended up breaking the plastic cap off the tip.
If you're having difficulty fitting them into the larger bore, it can be done carefully with a C vise clamp. Get a short well socket that fits over the fuel rail end of the injector. Place one tip of the C clamp against the socket and the other end inside the manifold passage underneath the injector bore. Only apply enough pressure to where you can clamp the vice grip with one hand. Once it's clamped, gently rock the injector/clamp back and forth. A little oil on the o-ring will help as well, and that method should work it into the bore.
If you're having difficulty fitting them into the larger bore, it can be done carefully with a C vise clamp. Get a short well socket that fits over the fuel rail end of the injector. Place one tip of the C clamp against the socket and the other end inside the manifold passage underneath the injector bore. Only apply enough pressure to where you can clamp the vice grip with one hand. Once it's clamped, gently rock the injector/clamp back and forth. A little oil on the o-ring will help as well, and that method should work it into the bore.
Lead Driver
Joined: Feb 2002
Posts: 7,960
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From: Greater Austin, Texas
Are you using new o-rings? If so, where did you get them? I put rebuilt injectors I bought off of eBay in my 460 and I had a hell of a time getting them to go in. One I absolutlely could not get to go in, so I used one of the old o-rings, and it popped right in. So I examined the o-rings that came with the injectors and, while they were the same size, they had a ridge on the outside circumference from the mold. I bought a complete set of new o-rings from Ford and, after that, they went right in without any fuss. I used wheel bearing grease to lube mine.
Cargo Master
Joined: Jul 2009
Posts: 2,541
Likes: 54
From: Des Moines
Ford Fuel Injection » Injectors
Go to that page and scroll down just a little bit- it's an illustration but it's close enough. The body of the injector should be about even with the top of the injector bore.
Go to that page and scroll down just a little bit- it's an illustration but it's close enough. The body of the injector should be about even with the top of the injector bore.
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Senior User
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Ok, that looks like how mine are. I guess I'll be able to tell if they're all the way in when I put the rail on...
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Joined: Jun 2006
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From: Ottawa, Ontario
This is what it should look like when assembled. It goes without saying the injector pockets in the lower intake have to be clean bofore starting this job, I always give them a little buffing with a small cartridge roll to remove any ozidation and built-up crud, and apply petrolium jelly to the O-rings before installation and they just pop in without much effort. If you scar or nick an 0-ring when assembling you will have a fuel leak so this has to go together nicely.
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