EV1 Injector Revamp and Install
 

IF YOU HAVE A COMMENT OR RECOMMENDATION, PM ME. DON'T POST IT ON THIS THREAD. ONLY QUESTIONS ARE ALLOWED.

Ford EV1 Injector Rebuild and Replacement

This is a pretty strait forward write-up of how I rebuilt a set of EV1 injectors for my truck. I’m sure there are many different ways to do this, but this is how I did it. The injectors I chose to use are 4 hole DRI injectors. The set I pulled came from a 1997 Ford Crown Victoria with a 4.6L. The reasoning for these new injectors was actually broken down into parts. First was the simple fact that my current injectors had 195K miles on them with no servicing to them. Next up is the reports I have heard that these injectors had the possibility of increasing mileage and efficiency. This is due directly to the 4 holes that allow for better atomization of the fuel, allowing it to burn more efficiently. Seemed worth it for ~$65 TOTAL. They are available in a number of vehicles, but were pulled the easiest from the Crown Vic.

Any of these SHOULD have them. If you happen to find any issue with this list, let me know.

93-94 Bronco 5.0L
93-94 Bronco 5.8L
92-98 Crown Victoria 4.6L
93-98 Crown Victoria Police Interceptor 4.6L
03 E-150 4.6L
03 E-150 5.4L
03 E-150 Club Wagon 4.6L
03 E-150 Club Wagon 5.4L
93-94 E-150 Econoline 5.0L
93-94 E-150 Econoline 5.8L
97-02 E-150 Econoline 4.6L
97-02 E-150 Econoline 5.4L
93-94 E150 Econoline Club Wagon 5.0L
93-94 E150 Econoline Club Wagon 5.8L
97-02 E150 Econoline Club Wagon 4.6L
97-02 E150 Econoline Club Wagon 5.4L
03 E-250 5.4L
93-94 E-250 Econoline 5.8L
97 E-250 Econoline 4.6L
97-02 E-250 Econoline 5.4L
03 E-350 5.4L
03 E-350 Club Wagon 5.4L
93-94 E-350 Econoline 5.8L
97-02 E-350 Econoline 5.4L
93-94 E-350 Econoline Club Wagon 5.8L
97-02 E-350 Econoline Club Wagon 5.4L
00-02 E-450 Econoline Super Duty 5.4L
00-02 E-450 Econoline Super Duty Stripped 5.4L
97-98 Econoline Super Duty 5.4L
00-04 Excursion 5.4L
97-02 Expedition 4.6L
97-02 Expedition 5.4L
93-94 F-150 5.0L
93-94 F-150 5.8L
93-94 F-150 Lightning 5.8L
97-03 F-150 4.6L
97-03 F-150 5.4L
93-94 F-250 5.0L
93-94 F-250 5.8L
97-99 F-250 4.6L
97-99 F-250 5.4L
99-03 F-250 Super Duty 5.4L
93-94 F-350 5.8L
99-03 F-350 Super Duty 5.4L
92-97 Grand Marquis 4.6L
94 Thunderbird LX 4.6L
94 Cougar XR7 4.6L
96-04 Mustang GT 4.6L
98-01 Lincoln Navigator 5.4L
91-93 Lincoln Town Car 4.6L

Here are the part numbers for the injectors:

OEM 0280150909 BOSCH
OEM 0280150939 BOSCH
OEM 0280150943 BOSCH
OEM CM-4714 MOTORCRAFT
OEM CM-4718 MOTORCRAFT
OEM CM-4719 MOTORCRAFT
OEM F0TZ-9F593-C FORD
OEM F0TZ-9F593-DA FORD
OEM F1TZ-B FORD
OEM F1VY-A FORD
OEM FOTE-B1A FORD
OEM FOTE-D1A FORD
OEM FOTE-D5A FORD
OEM FOTZ-C FORD

Again, any issues with what are posted, let me know.
Here are the physical differences between the Pintle style and DRI style injectors.

Pintle:
https://www.supermotors.net/getfile/...or--pintle.jpg

DRI:
https://www.supermotors.net/getfile/...ector--dri.jpg

On to the rebuild.

Here are all the tools you will need for disassembly:

https://www.supermotors.net/getfile/...e/img_0622.jpg

I started with a set of 8 dirty 4 hole injectors from the junkyard. All 8 of them did actuate when a voltage was applied to them, so I knew they at least worked. Here they are in all their filth.

https://www.supermotors.net/getfile/...e/img_0611.jpg

The basic break down process of the injectors was quiet simple. It’s just the pintle cap, 2 O-Rings, a nylon spacer and the injector filter.
To remove the pintle cap, you simply take a small flat head screw driver and pry it up under the cap between it and the O-Ring. Work around it in all directions and it should eventually come off.

https://www.supermotors.net/getfile/...e/img_0625.jpg

Once the cap is off the O-Ring and nylon spacer simply slides off.

https://www.supermotors.net/getfile/...e/img_0626.jpg

https://www.supermotors.net/getfile/...e/img_0627.jpg

On to the other side. I started off by removing the O-Ring from the injector. Slide the blade of a flat head screw driver under the O-Ring and pop it over the lip.

https://www.supermotors.net/getfile/...e/img_0623.jpg

https://www.supermotors.net/getfile/...e/img_0624.jpg

Once the O-Ring is off, we move onto the removal of the filter. What you need is a #10 machine screw and a couple of nuts whose inner cutout is larger than the diameter of the filter itself.

https://www.supermotors.net/getfile/...e/img_0628.jpg

Once you have started the threads of the screw, simply tighten it till the filter is pulled out of the injector.

https://www.supermotors.net/getfile/...e/img_0629.jpg

To remove the screw from the filter, grab the brass ring of the filter with vise grips and back the screw out.

https://www.supermotors.net/getfile/...e/img_0630.jpg

That’s all there is to disassembly. Really strait forward. Took 10 minutes to do all 8.

https://www.supermotors.net/getfile/...e/img_0631.jpg

https://www.supermotors.net/getfile/...e/img_0632.jpg

Next up is cleaning of the injectors. I used 2 small coffee cans and 1 can of Berryman B12 Chemtool Fuel injector cleaner. Fill till the injectors are submerged. This stuff is strong. The moment I poured the cleaner into the cans with the injectors, the dirt, grease and filth covering the injector lifted off. The varnish started to flow out and the paint on the injectors turned to liquid.

https://www.supermotors.net/getfile/...e/img_0636.jpg

https://www.supermotors.net/getfile/...e/img_0637.jpg

Overall I plan to use about 3 cans of the cleaner. I would recommend buying three.

After allowing to soak overnight, I poured out the black gunky fluid and put them in a car of fresh cleaner for half an hour before blowing compressed air through them.

I didn't take any pictures of the set up, but it simply was a plug for the injectors wired to a Dewalt drill battery with a momentary switch. Set it up so that when I pressed the switch and opened the injector, the air blew BACKWARDS through the injector taking any and all gunk with it.

I then re-painted them with some cheap $.97 flat black spray paint to prevent rust. i have used this stuff before and it hold up just fine.

https://www.supermotors.net/getfile/...e/img_0640.jpg

Here is the re-build kit. Has everything I need to get them finished. $20.38 shipped to my door. Here is the link again:
Bosch EV1 Rebuild Kit

https://www.supermotors.net/getfile/...e/img_0641.jpg

I started off by pressing the filters in. I started them by hand, them finished getting them flush with a large c-clamp.

https://www.supermotors.net/getfile/...e/img_0645.jpg

https://www.supermotors.net/getfile/...e/img_0646.jpg

https://www.supermotors.net/getfile/...e/img_0644.jpg

Then I placed the first O-Ring on the same end.

After that, I went onto the other side. Slide the spacer on first, then the O-Ring.

https://www.supermotors.net/getfile/...e/img_0648.jpg

And last the pintle cap. Just lay it on the table, and press the injector into it. It will click into place.

https://www.supermotors.net/getfile/...e/img_0649.jpg

And there you have it. A set of rebuilt, cleaned injectors ready to go in.

https://www.supermotors.net/getfile/...e/img_0642.jpg

https://www.supermotors.net/getfile/...e/img_0650.jpg

Once the time frees up I will cover the process of removing the upper intake to replace the injectors. All should be done within the next week or two. I figured I might as well post what i have so I don't forget anything, and in case anyone happens to be needing to do this right now. Any and ALL comments and suggestions are welcome.

IF YOU HAVE A COMMENT OR RECOMMENDATION, PM ME. DON'T POST IT ON THIS THREAD. ONLY QUESTIONS ARE ALLOWED.

Rebuild complete as of 3/10/13. Up next is the intake removal and actual injector swap.

This is by no means a step-by-step with pictures, but it does a fairly good job of explaining. If you have any questions feel free to PM me.

1992 Ford F-150 Intake Removal for Injector Swap pictures, videos, and sounds | SuperMotors.net