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Fuel Injectors: Installation

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: DO NOT apply Threadlock® 620 to angled areas.
  1. Position the fuel injector sleeve onto the Injector Sleeve Replacer (303-D109, D94T-9000-C). Apply Threadlock® 620 to the very bottom (smallest diameter) and very top (largest diameter) flat areas. See Fig 1.
  2. Position the fuel injector sleeve into the cylinder head fuel injector bore. Seat the fuel injector sleeve in the fuel injector bore, using a rubber mallet. Remove injector sleeve replacer from the cylinder head fuel injector bore.
  3. Using the injector sleeve brush, part of Injector Sleeve Brush Set (303-DS110, D94T-9000-D), clean the fuel injector sleeve and bore. Remove any sealant residue from the fuel injector bore.
  4. Install NEW "O" rings on the fuel injector. See Fig 2. Lubricate the fuel injector and "O" rings liberally with clean engine oil. Install the cylinder heads.
    5. CAUTION: Remove all oil and fuel from the cylinders before installing the fuel injectors. Failure to do so can cause hydrostatic lock, resulting in severe engine damage. DO NOT strike the top of the fuel injector to seat the injector in the cylinder head fuel injector bore. Damage to the fuel injector can occur. Use hand pressure on the top of the fuel injector until the fuel injector hold-down plate is flush with the cylinder head.
  5. Using the Injector Replacer (303-492, T94T-9000-AH2), seat the fuel injector into the cylinder head fuel injector bore. See Fig 3. Install the fuel injector outboard retaining bolts and tighten to specification. See Figure. See TORQUE SPECIFICATIONS .
  6. Install the oil deflector on the fuel injector hold-down plate. See Figure. Install the oil drain plugs. See Figure. Tighten oil drain plugs to specification. See TORQUE SPECIFICATIONS . Tighten the fuel drain plug located at the rear of each cylinder head to specification.
  7. Position the valve cover gasket onto the cylinder head. Install the fuel charging wiring harness. Install the valve covers. See VALVE COVERS .
Fig 1: Applying Sealant On Fuel Injector Sleeve
G00211511Courtesy of FORD MOTOR CO.
Fig 2: Locating Back-Up Ring, Cushion Rings, Seals & Copper Washer On Fuel Injector
G99G03799Courtesy of FORD MOTOR CO.
Fig 3: Installing Fuel Injector
G00211512Courtesy of FORD MOTOR CO.
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