Katerina Swanson
The Ford Fusion is a midsize sedan known for its comfortable cabin, strong build quality, and family-friendly qualities. One of the most important components of the Ford Fusion is its fuel injection system, which includes the fuel injectors. Fuel injectors play a crucial role in the engine's performance, regulating the amount of pressurized fuel used for each cycle. While the number of fuel injectors in a Ford Fusion is not explicitly stated, it is generally understood that there is one injector per cylinder in an engine. This means that the number of fuel injectors in a Ford Fusion will depend on the number of cylinders in its engine.
Ford Fusion Fuel Injector Characteristics
| Characteristics | Values |
|---|---|
| Replacement Cost | $252 to $308 on average |
| Function | Regulate the amount of pressurized fuel used for each engine cycle |
| Number of Injectors | One injector per cylinder |
| Cleaning | Specialized cleaning and test equipment are required |
| Starting Issues | Clogged or damaged fuel injectors can cause starting issues |
| Engine Problems | Fuel injector failure can cause engine power reduction, misfires, and stalling |
| Fuel Odor | A leaking fuel injector can cause a fuel odor around the car |
| Check Engine Light | Illuminates when there is a fuel injection failure, such as a faulty solenoid |
| Deposits | All fuel injectors will accumulate deposits over time, which can affect performance |
| Replacement Procedure | Removal of the intake manifold, cables, hoses, wiring, supply and return lines, electrical connectors, and fuel rail |
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What You'll Learn
Fuel injector replacement cost
The cost of replacing a fuel injector on a Ford Fusion varies depending on the location and the complexity of the job. The average cost of the replacement is between $252 and $308, with labor costs estimated between $115 and $146, and parts priced between $136 and $162. This price range does not include taxes and fees and may not factor in your unique location.
Fuel injectors regulate the amount of pressurized fuel used for each engine cycle. There is one injector per cylinder in an engine. Each time an intake stroke occurs in the engine, the vehicle's computer will send a signal to the fuel injectors, requesting they spray fuel. For heavy acceleration, the duration of the fuel spraying will be longer than if the engine is idling.
When a fuel injector fails or clogs, engine power is reduced, and misfires will occur. The check engine light will turn on, and as the issue progresses, the engine may stall immediately after starting, fail to start, hesitate under throttle, or vibrate roughly. It is not recommended to drive a vehicle with a fuel injector problem as it can cause the car to stall and accelerate unpredictably, creating a hazard.
The injector has a solenoid and valve within, and the operation, or pulsing, of the solenoid is controlled by the powertrain control module (PCM). The PCM controls the solenoid’s “on” time to maintain the optimal air-fuel ratio while the engine load and operating conditions constantly change. Fuel injectors are usually connected to a fuel rail located on top of the engine, and the fuel rail is supplied with fuel under pressure from the fuel pump located in the fuel tank.
To replace a fuel injector, a technician will first conduct a visual inspection and, if the issue is unclear, connect a computerized scanner to read the vehicle's sensors. The fuel injector in question must be tested and may require removal for bench testing. Any failed components must be replaced, and the vehicle will be checked to ensure the problem is fixed. Typically, the intake manifold must be removed to access and replace the fuel injectors, which may involve draining the coolant and oil and removing many engine components.
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Symptoms of a faulty fuel injector
A fuel injector is a fuel metering device that sprays atomized droplets of fuel into the engine's intake manifold or directly into the combustion chamber. There is one injector per cylinder in the engine of a Ford Fusion. When a fuel injector fails or gets dirty or clogged, engine power is reduced, and several issues can occur.
One of the most common symptoms of a faulty fuel injector is engine misfiring, which can make the motor feel like it is sputtering and send vibrations through the car. This can happen when a fuel injector problem disrupts the balance between fuel and air entering the engine. Rough idling is another common symptom, characterized by varying revolutions per minute (RPMs), even when your foot is off the gas pedal. Poor fuel mileage or a drop in fuel efficiency could also indicate that a faulty injector is delivering an improper amount of fuel to the engine.
A fuel smell or visible leaks around the car could indicate a leaking fuel injector. This could be due to the injector not closing properly or a crack in the injector itself. If the check engine light on your dashboard is flashing or illuminated, it could mean that the fuel injector is dirty or malfunctioning and supplying an incorrect amount of fuel to the engine. This will likely cause a decrease in overall engine performance and fuel economy.
If you suspect a problem with your fuel injectors, it is recommended to take your vehicle to a professional for inspection and repair. Fuel injector replacement or cleaning requires specialized tools and knowledge, and improper handling can lead to further damage or safety hazards.
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Fuel injector cleaning
Fuel injectors are one of the most vulnerable parts of a vehicle to getting clogged, dirty, and plugged. This can cause significant problems, as fuel injectors regulate the amount of pressurised fuel used for each engine cycle. Therefore, cleaning the fuel injectors on your Ford Fusion regularly is essential.
There are two main ways to clean your fuel injectors: using an additive or removing the injectors from the car and servicing them.
Using an Additive
This method is simple and can be done at home. First, fill up your gas tank and park your Ford Fusion on a flat surface where the gas cap side is accessible. Open the gas cap and pour a full bottle of a single-tank fuel injector cleaner into your gas tank. Close the gas cap and start your vehicle. Then, either go for a 20-minute drive or let your vehicle idle for 15 to 20 minutes. This will allow the injector cleaner to cycle and prevent it from sinking to the bottom of your tank.
There are many injector cleaner products available, such as Chevron Techron, Seafoam, Lucas, Royal Purple, and Red Line SI-1 (or SL-1). Some people also use a mix of Marvel Mystery Oil and Chevron Techron in a 1:1 ratio. It is recommended to use injector cleaners once or twice a year, depending on your mileage.
Servicing the Injectors
This method requires removing the injectors from the car and using specialised cleaning and testing equipment. It is a more complex process and typically involves the following steps:
- Relieve the pressure within the fuel rail by running the engine briefly with the fuel pump fuse out.
- Remove the upper plenum and any cables, hoses, or wiring that restrict access to the intake manifold.
- Disconnect the supply and return lines from the fuel rail.
- Unlock and remove the electrical connectors to each fuel injector.
- Unbolt and remove the fuel rail from the intake manifold.
- Remove the injector(s) requiring replacement from the fuel rail, being careful to prevent any debris from entering the exposed openings.
- Service the injectors using specialised cleaning equipment.
- Reinstall the injectors and all the components that were removed.
It is important to note that some car manufacturers do not recommend using fuel system cleaning compounds or procedures unless specified. Always refer to your owner's manual or seek advice from a qualified technician before attempting any fuel injector cleaning or servicing.
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Fuel injector replacement procedure
The fuel injector replacement procedure for a Ford Fusion should be left to a professional, as the risk of fire is high, and the repair can be complicated. The average cost for a Ford Fusion Fuel Injector replacement is between $252 and $308, but this can vary from car to car.
If fuel delivery system symptoms are present, a technician will first conduct a visual inspection. If the issue is unclear, they will then connect a computerized scanner to read the vehicle's sensors. If there is a fuel injector problem, the technician will find that misfires are happening frequently on one cylinder. The injector(s) in question must be tested and may require removal for bench testing. Any failed components must be replaced, and the vehicle will be checked to ensure the problem is fixed. Typically, the intake manifold must be removed to access and replace the fuel injectors. This can be a large job that may involve draining the coolant and oil, removing many engine components, and replacing the intake manifold gasket. However, some cars are designed with plastic intake manifolds that do not have oil or coolant passages, making this process easier.
The fuel injectors should be serviced or replaced once the engine is cold, and the pressure within the fuel rail is relieved by briefly running the engine with the fuel pump fuse out. The upper plenum on the intake manifold is removed, along with any cables, hoses, or wiring that restricts access. The supply and return lines are removed from the fuel rail, and the electrical connectors to each fuel injector are unlocked and removed. The fuel rail is then unbolted and removed from the intake manifold. The injector(s) requiring replacement are removed from the fuel rail, taking care to not allow any debris to enter the exposed openings.
Using a new O-ring, the serviced or replaced injector is re-inserted into the fuel rail—using engine oil on the O-ring to prevent damaging it. The fuel rail is re-installed, and the supply and return lines are re-connected. The plenum is re-installed along with all cables, hoses, or wiring. Finally, the engine is run, and a careful check for leaks is performed before the vehicle is road-tested.
It is important to note that fuel system cleaning compounds or procedures should not be used unless specified by the manufacturer. On-car cleaning of fuel injectors is not as effective as off-car cleaning because injectors have tiny internal filter baskets that should be replaced as part of the servicing process.
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Fuel injector function
A fuel injector is a device that atomizes and injects fuel into an internal combustion engine. The injector atomizes the fuel and forces it directly into the combustion chamber at the precise point in the combustion cycle. The combustion chamber is where the chemical energy in diesel, hydrogen, and natural gas is converted into power for the vehicle.
Modern diesel engines are direct injection, meaning fuel is delivered directly into the combustion chamber. In the cylinder, air is compressed by the upward movement of the piston. As the piston nears the top of its path, an electrical signal is sent to the solenoid, causing the injector needle to lift, and allowing high-pressure fuel to flow through the nozzle and into the combustion chamber to mix with air. The air-fuel mixture is then ignited, creating power and driving the engine's pistons.
The latest fuel injector technology helps reduce carbon and greenhouse gas emissions by delivering accurate fueling with optimized air mixing. Fuel injectors with optimized air mixing enable an engine to generate maximum power while minimizing fuel consumption and reducing pollution. The combination of high fuel pressure and exceptionally fine injector nozzle holes ensures optimal mixing of air and fuel to meet even stricter emissions standards.
Fuel injectors are more than just a component in engines. They can play a key role in the energy transition from fossil fuels to cleaner energy sources, such as hydrogen fuel cell vehicles. Hydrogen fuel cell vehicles harness electrical energy produced by splitting a hydrogen atom into protons and electrons and reacting it with oxygen. The hydrogen delivery system must provide a sufficient fresh flow of hydrogen to the anode side of the fuel cell stack to meet the electrical power demands of the application. This can be accomplished using either a hydrogen injector or proportional valve, both of which accurately regulate the flow of hydrogen to the stack.
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Frequently asked questions
A Ford Fusion has one fuel injector per cylinder in its engine.
There are several signs that your Ford Fusion's fuel injectors may be faulty, including:
- A fuel odor around your car
- Poor engine operation, such as rough idle, loss of power, or misfiring
- The check engine light is illuminated
If you suspect that your Ford Fusion's fuel injectors are faulty, you should not drive the vehicle as it could be hazardous. Instead, take it to a technician to have the fuel injectors tested and, if necessary, removed and replaced.
