Replacing Fuel Injectors In A 2010 Ford Expedition: Step-By-Step Guide

If you're experiencing problems with your 2010 Ford Expedition, you may need to replace the fuel injector. Fuel injectors regulate the amount of pressurised fuel used for each engine cycle, and when they fail or clog, engine power is reduced and the engine may stall or fail to start. While it's not recommended to drive with a faulty fuel injector, you can replace it yourself or call a mechanic to do it for you. The cost of replacement will depend on your location, but you can expect to pay between $500 and $900.

Disconnecting the battery and taking fire precautions

Firstly, always disconnect the battery before starting any work involving fuel. Locate the battery in the engine bay and identify the negative terminal, which is usually marked with a "-" symbol or a black cover. Use an appropriate-sized wrench or socket to loosen the nut on the negative terminal and carefully lift the cable away from the battery. Ensure that the cable does not touch any metal parts of the vehicle during this process.

Secondly, take fire precautions. Working with fuel can be hazardous, and it is essential to minimize the risk of fire or explosion. Before beginning any work, gather a fire extinguisher and keep it nearby in case of emergencies. Ensure that the work area is well-ventilated to prevent the buildup of flammable fumes. If possible, work outdoors or in a well-ventilated garage with the doors open. Avoid smoking or any open flames near the vehicle. Keep a bucket of water and rags nearby to clean up any spilled fuel immediately.

Cover or protect any electrical components or sensitive engine parts that may be exposed during the fuel injector replacement process. Fuel can damage electrical connectors and components, so it is crucial to take precautions to avoid any accidental spills or leaks.

Additionally, wear the appropriate personal protective equipment (PPE), such as safety goggles, gloves, and a respirator. These will protect your eyes, skin, and lungs from any harmful chemicals or fumes. Place a drip pan or container under the work area to catch any fuel that may leak during the replacement process.

Before starting the replacement process, relieve the pressure in the fuel system. Run the engine briefly with the fuel pump fuse removed to release the pressure within the fuel rail. This will prevent fuel from spraying out when you disconnect the fuel lines and injectors.

When working on the fuel injector, be cautious of the O-ring seals. These seals can be easily damaged or torn, so handle them with care. It is recommended to have a few replacement O-rings on hand in case of damage during the repair. Lubricate the new O-rings with a light coat of engine oil or Vaseline before installing them to prevent tearing and ensure a proper seal.

Finally, always refer to a repair manual or seek advice from a qualified mechanic if you are unsure about any part of the process. Working with fuel can be dangerous, and it is essential to take the necessary precautions to ensure your safety.

Removing the intake manifold

To remove the intake manifold, you will first need to relieve the pressure within the fuel rail. Do this by briefly running the engine with the fuel pump fuse removed.

Next, remove the upper plenum on the intake manifold, as well as any cables, hoses, or wiring that may restrict access. Remove the supply and return lines from the fuel rail, and then unlock and remove the electrical connectors to each fuel injector. Now, unbolt and remove the fuel rail from the intake manifold.

You will then need to remove the injector(s) requiring replacement from the fuel rail, being careful not to let any debris enter the exposed openings. Typically, an O-ring seal holds the injector very firmly in a finely polished bore in the fuel rail.

Note that you may not need to remove the upper intake manifold to get at the bolts holding the fuel injection supply manifold (fuel rail) in place. If you are only replacing one injector, you can simply remove the two fuel rail bolts on the driver's side and lift the fuel rail up.

Disconnecting the fuel injector

Firstly, ensure the engine is cold. This is important for safety reasons, as you will be working with fuel. Then, relieve the pressure within the fuel rail by briefly running the engine with the fuel pump fuse removed. This will prevent any accidental spraying of fuel when you start to disconnect components.

Next, locate the upper plenum on the intake manifold, as well as any cables, hoses, or wiring that may restrict access to the fuel rail and injector. Remove these carefully, taking note to unplug each injector's electrical connector. You may need to refer to a manual to identify the correct injector, as some models have eight injectors, and one of these is usually harder to access due to limited space.

Once you have located and disconnected the electrical connectors, you can remove the fuel rail. The fuel rail is held in place by bolts, usually two, that attach it to the intake manifold. Remove these bolts and carefully lift or yank the fuel rail away. Now you can access the injector requiring replacement.

At this point, you will need to remove the injector from the fuel rail. This may require some force, but be careful not to damage any components or allow debris to enter the exposed openings. An O-ring seal usually holds the injector firmly in place, so you may need to use a suitable tool to carefully prise it out.

Now that you have disconnected the fuel injector from the fuel rail, you can prepare to install the new injector or service the existing one. Remember to take appropriate fire safety precautions when working with fuel, and always refer to a qualified mechanic if you are unsure about any steps in the process.

Installing the new fuel injector

To install the new fuel injector, follow these steps:

Firstly, ensure the engine is cold. This is important for safety reasons. Then, relieve the pressure within the fuel rail by briefly running the engine with the fuel pump fuse removed. This will ensure any remaining fuel is released, reducing the risk of leaks and accidents.

The next step is to remove the upper plenum on the intake manifold, along with any cables, hoses, or wiring that may restrict access to the fuel rail and injectors. Once you have clear access, remove the supply and return lines from the fuel rail, and then unlock and remove the electrical connectors to each fuel injector. With these disconnected, you can now unbolt and remove the fuel rail from the intake manifold.

Now, carefully remove the faulty injector from the fuel rail, being mindful not to let any debris enter the exposed openings. This step may require some force, but the injector will come out. It is held in place by an O-ring seal, which you should be careful not to damage.

Take your new injector and, using a new O-ring, insert it into the fuel rail. You can use engine oil on the O-ring to prevent any damage and ensure a smooth insertion. Ensure the O-ring is a tight fit to prevent fuel leaks.

Finally, reinstall the fuel rail, reconnect the supply and return lines, and reattach the plenum and all cables, hoses, and wiring. Run the engine and carefully check for any leaks. If there are no leaks, take your Ford Expedition for a road test.

Reassembling the components

Once you have removed the faulty fuel injector and replaced it with a new one, you can begin reassembling the components.

First, using a new O-ring, insert the new injector into the fuel rail. It is important to lubricate the O-ring with engine oil to prevent any damage. O-rings fit very tightly to prevent fuel leaks, so ensure it is securely in place. Next, re-install the fuel rail by bolting it back onto the intake manifold. Re-connect the supply and return lines to the fuel rail.

Now, you can replace the upper plenum on the intake manifold, along with any cables, hoses, or wiring that you had to remove to access the fuel injector. Ensure everything is securely connected and bolted down.

Finally, start the engine and carefully check for any leaks. It is recommended to road test the vehicle to ensure the new fuel injector is functioning correctly.

It is important to note that working with fuel can be dangerous, so always take the necessary precautions and consider seeking professional assistance if you are unsure about any part of the process.

Frequently asked questions