Section 03-04C: Fuel Charging and Controls, 7.5L Engine
1996 F-250, F-350 and F-Super Duty Vehicles Equipped with 7.5L MFI V-8 Engines Workshop Manual
REMOVAL AND INSTALLATION

Fuel Injectors

Removal

  1. Perform pre-service procedures as described in Fuel Charging System in the Removal and Installation portion of this section.

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

  1. Remove fuel injection supply manifold (9F792) as described in Fuel Injection Supply Manifold in the Removal and Installation portion of this section.

  1. Carefully remove electrical harness connectors from individual fuel injectors (9F593) as required.

  1. Grasping injector body, pull up while gently rocking fuel injector from side to side.

    ItemPart NumberDescription
    19D930Fuel Charging Wiring
    29F792Fuel Injection Supply Manifold
    39F593Fuel Injector
    49424Intake Manifold, Lower
    556105-S2Bolt
    A—Tighten to 8-12 Nm
    (70-105 Lb-In)

  1. Inspect injector O-rings (two per injector) for signs of deterioration. Replace as required.

  1. NOTE: End cap is not available as a separate part.

    Inspect injector end cap and washer for signs of deterioration. Replace complete fuel injector as required. If end cap is missing, look for it in intake manifold.

Installation

  1.  CAUTION: Never use silicone lubricant. It will clog the fuel injectors.

    Lubricate new O-rings with light grade oil XO-10W30-QSP or equivalent meeting Ford specification ESE-M2C153-E and install two on each fuel injector.

  1. Install fuel injectors. Use a light, twisting, pushing motion to install them.

  1. Install fuel injection supply manifold as described in Fuel Injection Supply Manifold in the Removal and Installation portion of this section.

  1. Install electrical harness connectors to fuel injectors.

  1. Install upper intake manifold. Refer to Section 03-01C.

  1. Perform post-service procedures as described in Fuel Charging System in the Removal and Installation portion of this section.