Sylvie Willis
If you want to remove the fuel injectors from a 99 Explorer, you'll need to relieve the fuel pressure at the shredder valve, remove the upper intake, and disconnect the fuel lines from the fuel injection rail. You'll also need to disconnect the EGR tube from the exhaust manifold, as well as all vacuum lines, the throttle cable assembly, coolant hoses, ignition coils and wires, and the air intake ducting. Once you've done that, you can pop out the injectors from the lower intake and remove them from the fuel manifold. Be careful when handling fuel, as spilled fuel can cause an engine fire if not cleaned up properly. It's also worth noting that the 99 Explorer has a returnless fuel system. If you're looking to relieve fuel pressure, you can loosen the bolt on top of the fuel filter.
Removing Fuel Injectors from a 1999 Ford Explorer
| Characteristics | Values |
|---|---|
| Tools Required | 1 & 1/16" wrench, Allen wrench, flat screwdriver, pliers, slide hammer, tweezer/wheel puller tool |
| Steps | Disconnect EGR tube from the exhaust manifold, disconnect all vacuum lines, throttle cable assembly, coolant hoses, ignition coils and wires, and air intake ducting. Disconnect all electrical connections (DPFE sensor, MAP sensor, MAF sensor, TPS sensor). Remove upper intake, then remove injectors from lower intake and fuel manifold. |
| Tips | Tape under bolt head to prevent protrusion at the bottom, cut harnesses to easily remove and unplug injectors. |
| Common Issues | Difficulty removing plugs, tight engine space, difficulty removing and reseating upper intake manifold, EGR tubing fitting may be tough to remove if never disconnected before. |
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What You'll Learn
Relieve fuel pressure at the shredder valve
To relieve fuel pressure at the Schrader valve, you will need a rag and a small device of your choice to depress the valve. The process is similar to that of a tire valve. You can use a cheap dial-type air pressure gauge, or a plastic Lisle set, which is available on Amazon.
First, place a rag around the valve. Then, slowly press the centre pin of the valve in to release gasoline.
Alternatively, you can relieve fuel pressure by unplugging the switch under the passenger's side foot area. Then, crank the truck over for a second to relieve the pressure.
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Disconnect the EGR tube from the exhaust manifold
Disconnecting the EGR tube from the exhaust manifold of a 1999 Ford Explorer can be a challenging task, but it is achievable with the right tools and techniques. Here is a detailed guide to help you through the process:
First, it is important to understand the components involved. The EGR (Exhaust Gas Recirculation) tube is part of the EGR system, which is responsible for reducing nitrogen oxide emissions from your Explorer's engine. Over time, the EGR tube may become clogged or faulty, requiring removal or replacement.
Before beginning the disconnection process, ensure you have the necessary tools on hand. You will need a 1 & 1/16" wrench for the EGR fitting, as well as a deep well socket for the 13mm bolt located underneath the dipstick bracket. Additionally, you may require a regular wrench for other bolts.
Now, let's guide you through the steps:
- Locate the EGR tube and the exhaust manifold. The EGR tube is usually attached to the intake manifold and connected to the exhaust manifold or block. It may appear as if the tube is welded to a bracket that is hooked onto the exhaust manifold.
- Identify the bolts securing the EGR valve to the tube and exhaust manifold. There may be multiple bolts, including one that holds the EGR valve onto the tube and another smaller bolt underneath the dipstick bracket.
- Start by removing the bolts attaching the EGR valve. Depending on your Explorer's configuration, there may be a 27mm bolt holding the EGR valve in place. Remove this bolt using the appropriate-sized wrench.
- Next, address the smaller bolt underneath the dipstick bracket. As mentioned earlier, this bolt may be a 13mm bolt, and due to space constraints, a deep well socket may be required for this step. Carefully loosen and remove this bolt without pinching any nearby lines.
- Once all the bolts are removed, attempt to detach the EGR tube from the exhaust manifold. This step may require some force, as the tube may be stuck or sealed with an O-ring. Wiggle and lift the EGR tube away from the exhaust manifold to separate the two components. Be careful not to damage any surrounding components during this process.
- Finally, with the EGR tube disconnected, you can proceed with any necessary maintenance or replacement procedures. Ensure that you follow proper safety protocols and refer to a trusted repair manual for additional guidance if needed.
Remember, this process may vary slightly depending on the specific configuration of your 1999 Ford Explorer. Always exercise caution and consult a professional mechanic if you are uncomfortable performing any of these steps.
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Disconnect electrical connections
Disconnecting the electrical connections is a crucial step when removing fuel injectors from a 1999 Explorer. Here is a detailed guide to help you through the process:
Firstly, it is important to understand the components involved in the process. The fuel injectors are connected to the fuel manifold and the upper intake. The upper intake, in turn, has various connections that need to be disconnected. These include the EGR tube, which connects to the exhaust manifold, the throttle cable assembly, coolant hoses, ignition coils and wires, and the air intake ducting.
Now, to begin the process, locate and disconnect all the electrical connections associated with the upper intake. This includes sensors such as the DPFE sensor, MAP sensor, MAF sensor, and TPS sensor. Disconnecting these sensors from their respective connectors will ensure that the upper intake can be safely removed without causing any damage to the electrical systems.
Next, you will need to remove the upper intake itself. As mentioned earlier, the upper intake is connected to several components, so it is important to carefully disconnect each of these before attempting to remove the upper intake. Start by disconnecting the EGR tube from the exhaust manifold. Then, move on to the throttle cable assembly, coolant hoses, ignition coils and wires, and the air intake ducting, ensuring that you disconnect them in a systematic manner.
Once all the connections have been carefully disconnected, you can now focus on the fuel injectors themselves. With the upper intake out of the way, you will have access to the fuel injectors in the lower intake. At this point, you can "pop" or "wiggle" the injectors out. It is important to note that the injectors may be tightly connected, so using tools like an Allen wrench to depress the clip and a flat screwdriver to pry simultaneously might be necessary.
Finally, with the fuel injectors removed, you can now proceed with any maintenance or replacement work required. Remember to follow the manufacturer's guidelines and safety procedures during the entire process, and ensure that all tools and components are handled with care to avoid any damage or injury.
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Remove upper intake
To remove the upper intake on a 1999 Ford Explorer, you will need to perform the following steps:
Firstly, disconnect the battery ground cable and set it aside, ensuring it does not touch any metal. Place a drain pan under the radiator petcock and loosen it to allow the antifreeze mixture to drain. If the antifreeze is clean and less than five years old, you can reuse it.
Next, disconnect the EGR tube from the exhaust manifold. You can do this by removing the nut that holds the oil dipstick in place, then raising the dipstick just enough to clear the stud. You will then see another bolt head, which holds the EGR tube in place. Unscrew this bolt to release the tube.
Now, disconnect 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. Label all electrical wiring and vacuum lines attached to the upper intake manifold with masking tape and a marker. Remove the accelerator cable's brackets but leave the cable in the brackets.
At this point, you should also disconnect the EGR spacer or the throttle body coolant hoses, depending on your vehicle's configuration. Label the spark plug wires so you can reinstall them later onto the proper cylinder. Pull the plug wires off the coil packs and unplug the ignition coil wiring harness from the ignition coil. Remove the coil packs from the engine with the appropriate socket.
Now, focus on the bolts. There should be six bolts retaining the upper intake manifold. Two on the right, two on the left (these are shorter bolts), and two longer bolts in the middle. Label and loosen the bolts in numerical order.
Once the bolts are loosened, you can lift the upper intake manifold off of the lower intake manifold. Clean the gasket mating surfaces with a scraper and a rag, being careful not to gouge the intake manifold.
Finally, with the upper intake removed, you can access and remove the fuel injectors from the lower intake manifold.
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Remove injectors from lower intake
To remove the injectors from the lower intake of a 1999 Ford Explorer, you will first need to remove the upper intake. This involves disconnecting the EGR tube from the exhaust manifold, disconnecting 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 a little 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 the upper intake is off, you can pop" out the injectors from the lower intake. You can remove them from the fuel manifold and replace them.
The most difficult parts of this process are the removing and the reseating of the upper intake manifold and getting the tubing/hose that connects to the PCV unrouted and rerouted in the right place. If the EGR tubing fitting to the exhaust manifold has never been disconnected before, it may be tough to remove. You also have 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.
Additionally, the injectors just pull out from the center head once the fuel rail is off.
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Frequently asked questions
To remove the fuel injectors from your 99 Explorer, you need to first relieve the fuel pressure at the shredder valve. Then, remove the intake manifold upper plenum to access the injectors. Disconnect the fuel lines from the fuel injection rail and remove the injector rail bolts that hold it to the intake manifold. Once this is done, gently pry up on one injector until it pops out of the intake and repeat this process for each injector.
The best way to remove the injectors is to first relieve the fuel pressure. Then, remove the upper intake by disconnecting the EGR tube from the exhaust manifold, the vacuum lines, the throttle cable assembly, coolant hoses, ignition coils and wires, and the air intake ducting. Once the upper intake is off, you can pop out the injectors from the lower intake.
To disconnect the fuel injector electrical connectors, squeeze the plastic hooks molded into the connector body and the connector should slide right out.
The trick to removing the fuel injectors is to get all the plugs off the injectors first. You can use an Allen wrench to depress the clip and a flat screwdriver to pry at the same time. Once the plugs are off, remove the wiring harness from the rail and wiggle the rails out.
