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How to Replace Injectors on Ford E series Vans?

The details to replace Ford E series van injectors on diesel engine is as follows:----


Injectors
REMOVAL & INSTALLATION procedure is mentioned below:----


  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable.
  3. Remove the valve covers. For additional information, refer to the following section, -Valve Covers, Removal & Installation.-
  4. Disconnect the fuel injector electrical connector.
  5. Loosen the crankcase-to-head tube(s).
  6. Position the crankcase-to-head tube and separate the tube.
  7. Remove the 9 bolts and the high-pressure oil rail.
    WARNING
    Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support these components.
  8. If the crankcase-to-head tube separated, using the High Pressure Supply Tube Remover, remove the lower crankcase-to-head tube.
  9. Inspect the D-ring seals for damage (nicks, cuts and gouges). If damaged, replace the crankcase-to-head tube.
  10. Using the Injector Connector Release Tool, push the fuel injector electrical connector out of the rocker arm carrier.
  11. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
  12. Loosen the bolt and remove the bolt and fuel injector hold-down assembly and the fuel injector. Remove and discard the O-ring seals and copper washer.
To install:
  1. Install new O-ring seals and a copper washer on the fuel injector.
  2. Assemble the fuel injector hold down and bolt on the fuel injector and install the assembly. Tighten the hold down bolt to 26 ft. lbs. (35 Nm).

    Click image to see an enlarged view
    Fig. Injector installation-6.0L engine
  3. Remove the shop towels.
    NOTE
    Make sure the injector wiring is clear of all moving parts or engine damage can occur.
  4. Install the fuel injector electrical connector into the rocker carrier.
  5. Apply clean engine oil to the top fuel injector O-ring seals.
  6. Position the lower section of the crankcase-to-head tube in the engine.
  7. Position the high-pressure oil rail on the injectors.
  8. Place the high-pressure oil rail on top of the carrier so that the 4 single ball tubes are engaging the fuel injector lead angle.
  9. Insert the guide bolts, 2 on the ends of the straight side of the high-pressure oil rail and 1 in the middle of the wavy side of the high-pressure rail. Install the guide studs 6 to 7 turns.
  10. Manually press the high-pressure oil rail into the fuel injectors.
  11. Inspect that the high-pressure oil rail mounting feet are flat against the mounting surface.
  12. Loosely install the 6 high-pressure oil rail bolts.
  13. Remove the 3 guide bolts, install the remaining high-pressure oil rail bolts and tighten the bolts in the sequence shown to 115 inch lbs. (13 Nm).

    Click image to see an enlarged view
    Fig. High pressure oil rail torque sequence-6.0L engine
  14. Apply clean engine oil to the D-ring seals and reassemble the crankcase-to-head tube. Tighten the crankcase-to-head tube(s) to 60 ft. lbs. (82 Nm).
  15. Connect the fuel injector electrical connector.
  16. Install the valve covers.

This details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html



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