Friday, July 1, 2011

How to remove fuel injector on ford e 150 4.2 ?

Fuel Injectors


Removal & Installation




Early Build Models
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. If removing the right fuel injectors, remove the evaporator case.
  3. Remove the valve cover.
  4. Disconnect the fuel injector electrical connector.
  5. Disconnect the high-pressure oil rail supply line at the high-pressure oil rail.

    image

    Fig. Disconnect the high-pressure oil rail supply line at the high-pressure oil rail

  6. Remove the bolts and the high-pressure oil rail.

    Click image to see an enlarged view

    Fig. Remove the bolts and the high-pressure oil rail

  7. Disconnect and remove the high-pressure oil supply line.
    WARNING
    Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.

  8. Using a 19 mm socket, push the fuel injector electrical connector out of the rocker arm carrier.
    WARNING
    To prevent engine damage, do not use air tools to remove the fuel injectors. The clip that extracts the injector can dislodge and fall into the oil drain hole.


    NOTE
    There is no need to drain the fuel rail.


    NOTE
    If engine coolant is found in the combustion chambers, It may be necessary to install a new injector sleeve.

  9. Remove the bolt, fuel injector hold-down clamp and fuel injector.

To install:


WARNING
If the fuel injector oil inlet D-shaped O-ring is damaged, a new fuel injector must be installed.

  1. Install new O-ring seals and copper washer on the fuel injector. Lubricate the fuel injector and O-ring seals liberally with clean engine oil.
    WARNING
    To prevent engine damage, do not use air tools to install the fuel injectors. The clip that extracts the injector can dislodge and fall into the oil drain hole.

  2. Install the fuel injector, fuel injector hold-down clamp and bolt. Torque to 24 ft. lbs. (33 Nm).
  3. Install the fuel injector electrical connector into the rocker carrier.
  4. Apply engine oil to the top fuel injector O-ring seals.
  5. Install the high-pressure oil rail and bolts.
  6. Install the high-pressure oil rail.
  7. Install the bolts finger tight.
  8. Tighten the bolts in the sequence shown.

    image

    Fig. High pressure oil rail torque sequence

  9. Install the high-pressure oil line.
  10. Connect the fuel injector electrical connector.
  11. Install the valve covers.
  12. If removed, install the evaporator case.

Late Build Models
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove the valve cover.
  3. Disconnect the fuel injector electrical connector.
    WARNING
    To prevent engine damage, it is recommended that a new crankcase-to-head tube to installed each time it is removed. The D-rings are not replaceable. If you reuse the crankcase-to-head tube, you assume the risk for leakage. You must inspect each D-ring carefully for evidence of cutting, abrasion or twisting and never reuse a tube exhibiting any of these conditions.

  4. Remove the crankcase-to-head tube assembly.
    NOTE
    Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.

  5. Remove the bolts and the high-pressure oil rail.
    NOTE
    Use a shop towel and brake parts cleaner to remove the oil residue prior to removal.

  6. If the crankcase-to-head tube separated, use the special tool to remove the lower crankcase-to-head tube.
    WARNING
    Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.

  7. Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
  8. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
    WARNING
    Failure to account for all snaprings or pieces prior to placing the vehicle back in service can cause engine damage. A missing snapring can be ingested into the lube oil system, causing severe engine damage.


    WARNING
    To prevent engine damage, do not use air tools to remove the fuel injectors. The snapring that extracts the injector can dislodge and fall into the oil drain hole.


    NOTE
    There is no need to drain the fuel rail.


    NOTE
    If engine coolant is found in the combustion chambers, it may be necessary to install a new injector sleeve.


    NOTE
    Use a tool like Snap-On® SDMT440 Torx to avoid damaging the fuel injector plastic and to avoid interference with the evaporator case.

  9. Remove the bolt, fuel injector hold-down clamp and fuel injector.
    NOTE
    If a snapring or piece of a snapring is missing from the injector hold-down assembly, it must be located prior to removing the shop towels.

  10. Remove the shop towels.

To install:


WARNING
If the fuel injector oil inlet D-shaped O-ring is damaged, a new fuel injector must be installed.

  1. Install new O-ring seals and copper washer on the fuel injector. Lubricate the fuel injector and O-ring seals liberally with clean engine oil.
    WARNING
    Failure to tighten the injector correctly can lead to engine failure.


    WARNING
    To prevent engine damage, do not use air tools to install the fuel injectors. The snapring that extracts the injector can dislodge and fall into the oil drain hole.



    image

    Fig. Injector installation

  2. Install the fuel injector, fuel injector hold-down clamp and bolt. Torque to 24 ft. lbs. (33 Nm).
    WARNING
    Make sure the injector wiring is clear of all moving parts or engine damage can occur.

  3. Install the fuel injector electrical connector into the rocker carrier.
  4. Apply engine oil to the top fuel injector O-ring seals.
    NOTE
    Apply clean engine oil on the tubes prior to installing the oil manifold.

  5. Position the oil rail on the fuel injectors.
    1. Place the oil rail on top of the carrier so that the four single ball tubes are engaging the injector lead angle.
    2. Insert three bolts, two on the ends of the straight side of the oil rail and one in the middle of the wavy side of the rail. Install the guide studs six to seven turns.
    3. Press the oil rail into the fuel injectors.
    4. Make sure that the oil rail mounting feet are flat against the mounting surface.
    5. Loosely install the six bolts.

  6. Install the oil rail retaining bolts.
    1. Remove the three guide bolts.
    2. Loosely install three remaining bolts.

      image

      Fig. Oil rail bolt torque sequence

    3. Tighten the nine bolts in the sequence shown to 10 ft. lbs. (13 Nm).
      WARNING
      To prevent engine damage, it is recommended that a new crankcase-to-head tube to installed each time it is removed. The D-rings are not replaceable. If you reuse the crankcase-to-head tube, you assume the risk for leakage. You must inspect each D-ring carefully for evidence of cutting, abrasion or twisting and never reuse a tube exhibiting any of these conditions.


      NOTE
      Apply clean engine oil to the crankcase-to-head tube prior to installation.



      image

      Fig. Crankcase-to-head tube assembly


  7. Install the crankcase-to-head tube assembly. Torque to 60 ft. lbs. (82 Nm).
  8. Connect the fuel injector electrical connector.
  9. Install the valve covers.

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Fuel Injector Control Module

Removal & Installation





WARNING
Make sure the ignition switch is in the OFF position prior to working on the electronic engine controls.

  1. Turn the ignition switch to the OFF position.
    CAUTION
    Never remove the pressure relief cap while the engine is operating or when the cooling system is hot. Failure to follow these instructions can result in damage to the cooling system or engine or result in personal injury. To avoid having scalding hot coolant or steam blow out of the degas bottle when removing the pressure relief cap, wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the pressure is released from the cooling system. When certain all the pressure has been released, (still with a cloth) turn and remove the pressure relief cap. Failure to follow these instructions can result in personal injury.

  2. Before servicing the vehicle, refer to the Precautions Section.
  3. Relieve the cooling system pressure. Disconnect and plug or cap the engine vent hose and radiator vent hose.
  4. Remove the bolts and position the degas (coolant reservoir) bottle aside.
  5. On late build vehicles: Disconnect the two exhaust pressure (EP) sensor harness pin-type retainers. Disconnect the EP sensor electrical connector and position the harness aside.
  6. Remove the two bolts, two nuts and turbocharger intake tube bracket.
  7. Remove the fuel injector control module (FICM) bolts.
    WARNING
    Make sure both latches are released before removing the electrical connectors or connector damage can occur.



    image

    Fig. FICM bolts.

  8. Position out the FICM and disconnect the electrical connectors. Remove the FICM. To install, reverse the removal procedure.

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