Ford 7L5Z-9F593-AA
Injector

Safety measures should be a priority during fuel injector and fuel rail service since fuel components contain flammable mixtures therefore avoid open flames and smoking anywhere near these components. The first step includes decompressing fuel system pressure to stop unintended fuel spilling before disconnecting the battery ground cable. Detach the two nuts and bolt and remove the generator air inlet duct before disconnecting the fuel tube quick connect coupling from the fuel rail. Lift off the two wiring retainers from the fuel rail before removing the fuel rail insulator. The process requires separation of the two swirl control valve electrical connectors along with the four fuel injector electrical connectors. The assembly consists of removing the fuel rail together with fuel injectors after removing both fuel rail bolts. Eliminate and dispose of the eight seals used for the injector O-rings. The installation requires new special fuel-resistant O-ring seals which need lubrication with clean engine oil before installation. Always discard used seals. There are two procedures during installation: (1) Place fuel injectors along with retainer clips inside the fuel rail before (2) Reinstalling the fuel rail combined with fuel injectors using two fuel rail bolts which must be tightened to 23 Nm (17 lb-ft). Reconnect both of the swirl control valve electrical connectors and four fuel injector electrical connectors. Fit the fuel rail insulator before fastening both wiring harness retainers. Join the fuel tube quick connect coupling to the fuel rail. The generator air inlet duct should be reinstalled with two nuts and bolt and then tightened to 6 Nm (53 lb-in) before reconnecting the battery ground cable.

The service procedure includes fuel rail and fuel injector maintenance together as a single operation. Complete specifications for the analysis of fuel rail and fuel injector breakdowns can be found in sections which focus on fuel rail maintenance procedures.

Whenever you service fuel injector and fuel rail you must stay safe by keeping all fuel-related areas away from smoking or open flames because of present flammable mixtures. The initial process requires you to relieve fuel system pressure before removing the battery ground cable. First disconnect the fuel tube fast connector that connects to the fuel rail by removing the upper intake manifold. Begin by disconnecting both the electrical connector and the two wire harness retainers at the left side of the left valve cover stud bolts. The six fuel injector electrical connectors need disconnection while removing the two pin-type retainers securing the wiring harness cover. The first step requires disassembly of the fuel rail by removing its four bolts. The technicians extract the fuel rail and injectors together as one assembly and discard the twelve fuel injector O-ring seals. The installation process needs special fuel-resistant O-ring seals which should receive oil lubrication before six fuel injectors plus their clips are put inside the fuel rail. Secure the fuel rail along with its injectors as one assembly through the four bolts that demand 10 Nm (89 lb-in) torque. After reinstalling the wiring harness cover and pin-type retainers the technician should connect six fuel injector electrical connectors before using two wire harness retainers to bolt onto the left valve cover stud bolts. The battery ground cable should be reconnected while installing the upper intake manifold. Also connect the fuel tube quick connect coupling and ECT sensor electrical connector to the fuel rail.

Reinstall the upper intake manifold and reconnect the battery ground cable.