Fuel Supply Manifold and Injectors REMOVAL , INSTALLATION and TESTING on ford vehicles?

REMOVAL & INSTALLATION

See Figures 1 through 12

1. Remove the upper intake manifold. Be sure to depressurize the fuel system before disconnecting any fuel lines.
2. Disconnect the fuel supply and return line retaining clips.
3. Detach the vacuum line from the fuel pressure regulator.
4. Disconnect the fuel chassis inlet and outlet fuel hoses from the fuel supply manifold.

Fig. Fig. 1: Exploded view of the 2.3L and 2.5L engine fuel supply rail and injectors

Fig. Fig. 2: Exploded view of the 2.9L engine fuel supply rail and injectors

Fig. Fig. 3: Exploded view of the 3.0L engine fuel supply rail and injectors

Fig. Fig. 4: Exploded view of the 4.0L engine fuel supply rail and injectors

Fig. Fig. 5: Exploded view of the 5.0L engine fuel supply rail

Fig. Fig. 6: For fuel supply manifold removal, unbolt the upper intake, then disconnect the injector wire harness plugs

5. Label and disconnect the fuel injector wire harness plugs.
6. On the 2.3L and 2.5L engine, remove the two fuel supply manifold retaining bolts.
7. On the 4.0L (VIN X) engine, remove the six upper intake manifold attaching studs.

Fig. Fig. 7: On the 4.0L (VIN X) engine, remove the 6 manifold mounting studs which retain the supply manifold

8. On all other engines, remove the four fuel supply manifold retaining bolts.
9. Carefully disengage the fuel rail assembly from the fuel injectors by lifting and gently rocking the rail.

Fig. Fig. 8: Some models use small retaining clips to secure the injectors in the supply manifold

Fig. Fig. 9: Lift upwards with a rocking motion to disengage the injectors, then remove the supply manifold

Fig. Fig. 10: On the 4.0L engine, remove the old fuel supply manifold gasket and clean the mating surfaces

10. Remove the fuel injectors from the intake manifold by lifting while gently rocking them from side to side

Fig. Fig. 11: Remove the injectors from the engine by gently rocking it while pulling upwards

11. Place all removed components on a clean surface to prevent contamination by dirt or grease.

Never use silicone grease; it will clog the injector. All injectors and the fuel rail must be handled with extreme care to prevent damage to sealing areas and sensitive fuel metering orifices.

Fig. Fig. 12: The injector has O-rings at the nozzle (A) and at the fuel supply manifold (B). Replace any damaged seals

12. Examine the injector O-rings for deterioration damage, replacing them as needed.
13. Make sure the injector caps are clean and free from contamination or damage.

To install:

14. Lubricate all O-rings with clean engine oil, then install the injectors into the fuel rail using a light twisting/pushing motion.
15. On the 4.0L (VIN X) engine, position a new fuel rail gasket to the lower intake manifold.
16. Carefully install the fuel rail assembly and injectors into the lower intake manifold. Make certain to correctly position the insulators. Push down on the fuel rail to make sure the O-rings are seated.
17. Hold the fuel rail assembly in place and install the retaining bolts finger tight. Then tighten the bolts to specifications.
18. Connect the fuel supply and return lines.
19. Attach the vacuum hose to the fuel pressure regulator.
20. Connect the fuel injector wiring harness at the injectors.
21. Connect the vacuum line to the fuel pressure regulator, if removed.
22. Install the air intake and throttle body assembly.
23. Run the engine and check for fuel leaks.

TESTING

See Figure 13 and 14

Fig. Fig. 13: A noid light can be attached to the fuel injector harness in order to test for injector pulse

Fig. Fig. 14: Cross-sectional view of a typical MFI fuel injector

The fuel injectors can be tested with a Digital Volt-Ohmmeter (DVOM). To test an injector, detach the engine wiring harness connector from it. This may require removing the upper intake manifold or other engine components.

Once access to the injector is gained and the wiring is disconnected from it, set the DVOM to measure resistance (ohms). Measure the resistance of the injector by probing one terminal with the positive DVOM lead and the other injector terminal with the negative lead. The resistance measured should be between 11-4 ohms. If the resistance is not within this range, the fuel injector is faulty and must be replaced with a new one.

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