Exploring Fuel Injector Replacement In 1999 Ford Explorers

Replacing the fuel injectors on a 1999 Ford Explorer 5.0L V8 involves removing the upper intake by disconnecting the EGR tube from the exhaust manifold, detaching all vacuum lines, throttle cable assembly, coolant hoses, ignition coils, wires, and air intake ducting. You will need a 1 1/16 wrench for the EGR fitting and a suitable tool to remove the 8 bolts on the upper intake. Once the upper intake is off, the injectors can be popped out of the lower intake and replaced.

Disconnect the EGR tube from the exhaust manifold

Disconnecting the EGR tube from the exhaust manifold is a crucial step in changing the fuel injectors on a 1999 Ford Explorer. Here is a detailed, step-by-step guide on how to perform this task:

Firstly, locate the EGR tube and the exhaust manifold. The EGR tube, or Exhaust Gas Recirculation tube, is a part of the engine's emission control system. It connects to the exhaust manifold, which is the part of the engine that collects exhaust gases from multiple cylinders and directs them to the exhaust system. On the 1999 Ford Explorer, the EGR tube can be found connected to the exhaust manifold, typically near the back of the engine.

Once you have located the EGR tube and exhaust manifold, follow these steps to disconnect the tube:

• Prepare the necessary tools: Before beginning the disconnection process, ensure you have the right tools for the job. In this case, you will need a 1 & 1/16" wrench to remove the EGR fitting.
• Gain access to the EGR tube and exhaust manifold: Depending on the configuration of your engine, you may need to remove or move other components to access the EGR tube and exhaust manifold comfortably. This may include removing the upper intake manifold and disconnecting other components such as vacuum lines, coolant hoses, ignition coils, and air intake ducting.
• Loosen the EGR tube fitting: Using the appropriate wrench, loosen the fitting that secures the EGR tube to the exhaust manifold. Be careful not to strip the threads or damage the fitting, as this could lead to leaks.
• Separate the EGR tube from the exhaust manifold: Once the fitting is loosened, carefully separate the EGR tube from the exhaust manifold. Depending on how long the tube has been connected, there may be some resistance or buildup that makes it difficult to remove. Do not use excessive force, as this could damage the tube or manifold.
• Clean the connection area: Before proceeding, it is good practice to clean the connection area on the exhaust manifold and the end of the EGR tube. This will help ensure that any debris or buildup does not affect the sealing of the connection when the tube is reinstalled or replaced.
• Prepare for reinstallation: If you are planning to reinstall an EGR tube, make sure you have the necessary gaskets, seals, or other components required for a proper seal.

Remember, working on your vehicle's engine can be complex and requires a good understanding of automotive systems. Always refer to a qualified repair manual or seek the assistance of a professional technician if you are unsure about any steps or procedures.

Disconnect all vacuum lines, throttle cable assembly and coolant hoses

Disconnecting the vacuum lines, throttle cable assembly, and coolant hoses is a crucial step when changing the fuel injectors on a 1999 Ford Explorer. Here is a detailed guide to help you through the process:

Disconnecting the Vacuum Lines:

• Locate the vacuum lines: Vacuum lines are usually rubber hoses connected to various components of the engine, such as the intake manifold, throttle body, or brake booster.
• Start by identifying the vacuum lines that need to be disconnected. There may be multiple lines attached to different parts of the engine.
• Carefully detach the vacuum lines: Using a suitable tool, such as a flat-head screwdriver, gently pry or loosen the hose clamp that secures the vacuum line in place.
• Once the clamp is loose, carefully pull the vacuum line away from the connection point. It's important to do this gently to avoid damaging the hose or the connection.

Disconnecting the Throttle Cable Assembly:

• The throttle cable assembly is connected to the butterfly valve.
• Locate the throttle cable assembly: It is usually attached to the throttle body or near the carburettor.
• Disconnect the cable: You may need to loosen any clamps or fasteners holding the cable in place. Carefully detach the cable from the butterfly valve, ensuring that you don't bend or damage the cable.

Disconnecting Coolant Hoses:

• Coolant hoses are typically connected to the upper intake manifold and are responsible for circulating coolant throughout the engine to regulate temperature.
• Locate the coolant hoses: They are often made of rubber and connected to the engine with hose clamps.
• Drain the coolant: Before disconnecting the hoses, it's important to drain the coolant from the system to avoid spills. Place a drain pan under the radiator or coolant reservoir and open the drain plug to release the coolant.
• Disconnect the hoses: Using a wrench or a hose clamp plier, loosen the hose clamps and carefully detach the coolant hoses from the upper intake manifold.

Remember to work carefully and methodically when performing these steps. Ensure you have the necessary tools and safety equipment, and always refer to a trusted repair manual or seek advice from a qualified mechanic if you're unsure about any part of the process.

Disconnect electrical connections

Disconnecting the electrical connections is a crucial step in changing the fuel injector on a 1999 Ford Explorer. Here is a detailed, step-by-step guide to help you through the process:

Before beginning, ensure you have the necessary tools and safety equipment, including gloves and eye protection.

First, locate the electrical connections. These will include the DPFE sensor, MAP sensor, MAF sensor, and TPS sensor. The DPFE sensor, for instance, is typically located near the exhaust manifold. Once you have identified the sensors, carefully disconnect each of them, making sure to note their positions for easy reassembly.

Next, you will need to remove the upper intake. This will involve disconnecting several components, including the EGR tube from the exhaust manifold, vacuum lines, throttle cable assembly, coolant hoses, ignition coils and wires, and air intake ducting. When removing the throttle cable assembly, pay close attention to where it connects to the butterfly valve. Additionally, you will need a 1 & 1/16" wrench to disconnect the EGR fitting.

After removing the upper intake, you will have access to the fuel injectors. At this point, you can "pop" them out from the lower intake. Be cautious when removing the injectors, as they are delicate and can be easily damaged.

It is important to note that the process of disconnecting the electrical connections and removing the upper intake can be complex and time-consuming. Take your time and ensure you are comfortable with each step before proceeding. If you are unsure about any part of the process, it is recommended to consult a qualified mechanic or seek advice from a trusted forum or online resource.

Remove upper intake

To remove the upper intake on a 1999 Ford Explorer, you will need to follow a series of steps to ensure a safe and effective removal process. Here is a detailed guide to help you through the procedure:

Disconnect the Battery:

Disconnect the battery ground cable and set it aside safely, ensuring that it does not come into contact with any metal surfaces.

Prepare the Vehicle:

• Slide a drain pan under the radiator petcock.
• Loosen the petcock and allow the antifreeze mixture to drain into the pan. If the antifreeze is still usable, you can store it for reuse.

Remove Air Intake Components:

• Loosen the clamps on the air cleaner outlet tube using a screwdriver or appropriate socket.
• Remove the air cleaner outlet tube.
• Detach the crankcase ventilation hose from the throttle body.
• Unbolt and remove the throttle body shield using the appropriate sockets or wrenches.
• Disconnect the cables from the throttle shaft.

Label and Disconnect Electrical Components:

• Label all electrical wiring and vacuum lines attached to the upper intake manifold with masking tape and a marker for easy reassembly.
• Remove the accelerator cable's brackets but leave the cable in place within the brackets. Set the brackets aside.
• Disconnect the EGR spacer or the throttle body coolant hoses, depending on your vehicle's configuration.

Label and Remove Spark Plug Wires:

• Label the spark plug wires to ensure proper installation later.
• Pull the plug wires off the coil packs.
• Unplug the ignition coil wiring harness from the ignition coil.
• Remove the coil packs from the engine using the appropriate socket.

Remove the Intake Cover Plate:

• Unbolt and remove the intake cover plate with the appropriate socket.
• Detach any remaining wires and loom holders from the manifold if they are still connected.

Identify Upper Intake Manifold Retaining Bolts:

• Stand facing the engine so that the driver's side valve cover is on your right and the passenger side valve cover is on your left.
• Locate the upper intake manifold retaining bolts. There should be six of them: two on the driver's side, two on the passenger side (these are shorter bolts), and two longer bolts in the middle.

Loosen and Remove Upper Intake Manifold:

• Label and loosen the bolts in a specific order, such as numerical or alphabetical, to ensure proper reassembly.
• Carefully lift the upper intake manifold off of the lower intake manifold.
• Clean the gasket mating surfaces with a scraper and a rag, being cautious not to gouge the intake manifold.

By following these steps, you will be able to successfully remove the upper intake on your 1999 Ford Explorer. Remember to work carefully and refer to a repair manual if you need additional guidance.

Pop out the injectors from the lower intake

To pop out the injectors from the lower intake of a 1999 Ford Explorer, you will first need to remove the upper intake. This involves disconnecting several parts, including the EGR tube from the exhaust manifold, all vacuum lines, the throttle cable assembly where it connects to the butterfly valve, coolant hoses going to the upper intake, ignition coils and wires, and air intake ducting.

You will need a 1 & 1/16" wrench for the EGR fitting, and there are 8 bolts on the upper intake, with the one in the passenger back being particularly hard to find and access. You will also need to disconnect all the electrical connections (DPFE sensor, MAP sensor, MAF sensor, and TPS sensor).

Once you have removed the upper intake, you can access the injectors in the lower intake and "pop" them out. This step is relatively straightforward compared to the process of removing the upper intake manifold.

It is important to note that the most challenging parts of this process are removing and reseating the upper intake manifold and dealing with the tubing/hose that connects to the PCV. Additionally, if the EGR tubing fitting to the exhaust manifold has never been disconnected, it may be difficult to remove.

When reinstalling the upper intake, it is recommended to put the most rear driver's side bolt in the manifold first, as the firewall will not let you drop it in if the manifold is in the right location. You can use tape under the bolt head to prevent it from protruding at the bottom, and then remove the tape to let the bolt drop into its threaded hole once the manifold is seated.

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