Fuel injector question 96 3.8

Got around to doing the lower intake manifold gasket change. Everything came apart fine and looks good except the fuel injectors. One cap that goes on the spray end stuck in the head. I was able to get it out. The caps fit real tight though and I dont want to damage them to clean underneath. Anyone have a problem? The caps look rusty or discolored. Should I replace the o rings? Can you clean the orings with brake cleaner? Should I apply a small amount of oil on the o ring? I took everything off the manifold and plan on pressure washing it. Is there enough hose left if you cut off the quick connect to join it to the pipe with a hose clamp? It looks to short or like you would have to remove the stand off bracket its attached to. The thermostat housing ford sent me was not the same as original it was like the one pictured in Wiswins pictures. However my original did not have a fiber washer only the O ring one attached to the thermostat as in the picture. I noticed though Wiswin applied a fiber washer too. As far as I know my thermostat is original. It may have been replaced under warranty so Im not sure if I should installthe fiber washer too?? Funny thing, when removing the lower intake almost all bolts were only slightly more then hand tight. I could actually remove them with my fingers. No wonder Im having antifreeze in the oil.:screwy: Any help with injectors would be greatly appreciated. Thanks

An additional question. Did everyone install the injectors in the head first and then snap on the rail? or Did you hang all the injectors on the rail and install as a unit?

I would spray clean up inside the injector end cap.
I did have some of the end caps stay in the head when I lifted the injectors up.....and just cleaned them, and the spray end of the injectors with the spray fuel injection cleaner that they sell.....to spray into the intake to clean it up.
Up inside that end cap is the place that I have had junk build up that has caused a misfire issue on several occasions.....so I would certainly use the fuel injector cleaner spray to clean them up.
I am saying to use the spray so that you do not need to physically wipe the spray end of the injector....possibly causing a problem.....like forcing a bit of junk up into the small ports.
The spray will simply and easily flush the junk away.

You can buy a fuel injector "O" ring set if concerned about the condition of the ones you have.
I would use some oil.....the same as you put in the motor....on the end of your clean finger to put a light coating of oil onto the "O" rings before pressing the injectors into the head.
DO NOT use anything other than engine oil.....such as silicone grease as that would be very bad.

It is personal choice as to putting the injectors into the fuel rail first or into the head first.......just make sure that you get a very good connection between the fuel rail and the top of each injector.....you do NOT want any leaks there.

Another thing that I do, once I have the injectors and fuel rail fully in place.....and about all set to put the upper intake manifold in place.......but right before I put it on.......I turn the ignition key to the ON position....but do not crank the engine......and listen for the fuel pump to bring the fuel system up to pressure.
Then, I look over the fuel rail assembly to make sure that there are no leaks.......at this point, with the upper intake manifold not in place, you can get a real good look at the fuel rail connections to the fuel injectors.

Then, when you know that you do not have leaks, turn the ignition OFF and remove the key.....and procede to put the upper intake manifold in place and finish putting everything else back.

For the heater hose, with the damaged quick connect cut off.....I don't remember for sure, but I may have bent the bracket in order to make up for the slightly shorter hose.

For the Thermostat.....the fiber gasket, as I remember, is to seal the thermostat housing to upper intake manifold joint......preventing coolant leak outside the engine.
The factory connection may have been a liquid or paste gasket sealant?
The "O" ring gasket on the thermostat is to seal the water passage to prevent coolant from bypassing the thermostat by leaking around it....and also give the thermostat a nice firm seating....so that it does not rattle around.

wiswind
Thanks I will clean them before I put them in and oil the orings. I thought about ordering new ones just because of the miles on the car. I may check the price. Never mind just checked over $50.00 a piece. Thanks for all the help will post back with results.

I assembled the injectors on the fuel rail before installing but that was simply because I took the whole assembly off and took it inside to clean it. So I put it all back together at the table I was working at. I think it's a little easier to put those clips that hold the injector to the rail on before installing them.

I would agree that most likely.....installing the injectors on the fuel rail first is better.....
In any case, make sure that the seating area in the head is clean before pressing the injectors into it.

Also, the fuel injectors on the Windstar seem to be pretty reliable.
So I would feel confident with the originals
I did get a serious misfire right after the lower intake manifold gasket job.
On the advise of my mechanic, I used Berryman's B-12 Chemtool......and it took at least 4 treated tanks of gasoline (1 can each) to fully get it settled down.
I am guessing that I shook some dirt loose in all my moving things around.

Thanks for the ideas. I cleaned the heads real well and also pressure washed the manifold. Im waiting on a gasket for the egr valve. I removed the egr valve from the the manifold instead of trying to turn the large nut connected to it. Wiswind how did you completely flush your cooling system to change it over? My antifreeze is the green and it was real clean I changed it about 2 years ago.

Well, first off, mixing the 2 types, from what I have read a few places, is not a problem.
They are BOTH Ethylene Glycol coolant....the additive package is what is different....and the chemistry is compatable.

HOWEVER, if mixed.......the life of the G-05 will be the 2 years of the Green...and not the 5 years of the G-05.....even with a small quantity of the green.

I do not consider this to be a problem.....as I intended to flush again long before the 5 years.
In other words......I did not flush....flush....flush...and get ALL the green out......as that would be quite time consuming........but I did get most of it out......and you cannot see any sign of it in the end mix.......but even if I did....it would not hurt the system at all.
Just plan a 2 year service interval for the first time.....

I am not big on cleaners for the cooling system.....especially if it is clean, as you mention.

I would do a drain and fill......using a 50/50 mix of the coolant concentrate with distilled water......you might test the end mix to make sure.


Keep a REAL close eye on the temperature after you do the coolant change, as it can really spike up untill the air is burped from the system.
I watched mine real close...and when the temperature went up over 1/2 way.....I shut the engine down....and let it cool for a good while....then added coolant, and idled it again......

I finally got the egr gasket I was waiting for so I was going to start putting things together. I found Permatex makes a spray gasket remover and though I already had cleaned things I put it on and it works. I had not removed the egr gasket and it removed it with no hard scraping it peeled off. Just make sure you rrinse what ever your using thourougly as it will eat through stuff thats not metal. I also bought some spray injector throttle body cleaner to spray the injector tips but the tips are stuck on I had to use pliers to remove them. It left little knurrels from the plier jaws in them it didnt harm the top where the hole is. Do you think its critical. I also looked and the o rings are kind of worn dried out. Im wondering if I can buy new caps and o ring kits?? Any ideas? I figure its better to be safe then sorry. I agree that replacing the injectors is over kill. Thanks for the help.

You can get the O-rings at AZ or Advanced.

They have a better selection at Advanced:

http://www.partsamerica.com/ProductList.aspx?parttype=674&ptset=A&searchfor=Fuel+Injector+%22O%22+Ring+Kit

I don't know that the end cap can be bought on it's own.
It comes with the new injector.

If it is not damaged....I would put it back on and go with that.

In the future, I would leave the end cap in place, and just squirt the spray fuel injector cleaner up inside the end cap......the cleaner will flush out the junk.

Thanks for the information. I called team ford out of Las Vegas. Nice people they try and send everything if its in stock overnite. A bag of ten o rings 10.00 Why they wouldnt sell a bag of twelve I dont know. I ordered 2 bags. They will ship it next day for $6.00 Still cheaper then the local dealers when paying list. $17.00 a bag of ten plus tax. The caps are'nt really damaged I will use them they dont sell them except with a injector. I will put it together Friday night. Ill let you know how it goes.