Section 03-04A: Fuel Charging and Controls, 4.9L Engine
1996 Vehicles Equipped with 4.9L SFI Engines Workshop Manual
REMOVAL AND INSTALLATION

Fuel Injection Supply Manifold

 
SPECIAL SERVICE TOOL(S) REQUIRED
DescriptionTool Number
Spring Lock Coupling Disconnect ToolT81P-19623-G1
Spring Lock Coupling Disconnect ToolT81P-19623-G2

Removal

  1. Perform Pre-Service Procedures as described in Fuel Charging System in the Removal and Installation portion of this section.

  1. Remove the upper intake manifold (9424). Refer to Section 03-01A.

  1. Disconnect fuel tube retaining clips.

  1.  WARNING: RELIEVE FUEL SYSTEM PRESSURE BEFORE DISCONNECTING COUPLING.

    Using Spring Lock Coupling Disconnect Tool T81P-19623-G1 (3/8-inch) or T81P-19623-G2 (1/2-inch) or equivalents, disconnect fuel hoses at the fuel rail supply tube and fuel rail return tube.

    1. Fit tool to coupling so tool can enter cage to release garter spring.
    1. Push the tool into the cage opening to release female fitting from garter spring.
    1. Pull the coupling male and female fittings apart.
    1. Remove the tool from the disconnected coupling.

  1. Disconnect the vacuum line to the fuel pressure regulator (9C968).

  1. Remove the strap surrounding the fuel injection supply manifold (9D280), fuel charging wiring (9D930), and the main vacuum harness.

  1. Remove the three fuel injection supply manifold retaining studs.

  1. NOTE: Fuel injectors (9F593) will remain infuel injection supply manifold when removed.

    Remove fuel injection supply manifold.

  1. Grasp injector body and pull up while gently rocking fuel injector from side to side, to remove.

Installation

  1. Make sure injector caps are clean and free of contamination.

  1. Install the fuel injectors into the fuel injection supply manifold first to avoid damage to the O-rings.

  1. Secure the fuel injection supply manifold using the three retaining bolts. Tighten to 8-12 Nm (70-105 lb-in).

  1. Attach the vacuum line to the fuel pressure regulator.

  1. Secure the main vacuum harness and the fuel charging wiring to the fuel injection supply manifold with a strap positioned between the No. 5 and No. 6 intake manifold runners.

  1. Connect the fuel inlet and outlet tubes at the fuel injection supply manifold connections. Refer to the illustration.

    1. Check for missing or damaged garter spring. Remove damaged spring with small hooked wire.
    1. Install new spring if damaged or missing.
    1. Clean fittings.
    1. Install new O-rings.
    1. Lubricate with clean engine oil XO-10W30-QSP meeting Ford specification ESE-M2C153-E or equivalent.
    1. Assemble fitting by pushing with a slight twisting motion.
    1. To make sure of coupling engagement, visually check to be sure garter spring is over flared end of female fitting.

  1. Connect fuel tube retaining clips.

  1. Install the upper intake manifold as described in Section 03-01A.

  1. Perform Post-Service Procedures as described in Fuel Charging System in the Removal and Installation portion of this section.