Injector question re 96 Aerostar 4.0->92 Navajo.

[taylor0987]

I am putting a 96 Aerostar 4.0 engine into my 92 Navajo. I read Doug904's post and I'm clear about everything except if I need to swap the 92 fuel rail and injectors over to the 96 engine. It seems like they are all 19#ers but when I look up parts, the 92 injectors aren't the same as the 96s

Thanks.

 

[BrooklynBay]

If the engine already came with a fuel rail, and injectors, why wouldn't you want to transfer it as a whole? You could ask a Ford dealer if the injector part #s are interchangeable. Injectors are usually interchangeable, except when you are dealing with the Motorsport, hiflow injectors. They are made for more volume, and are only to be used with a modified, high performance system. Another thing to check would be the coil resistance on the injectors. Compare the 92 to the 96. Ford uses similar parts such as Bosch oxygen sensors, and other drive train control parts. Is the Mazda Navajo a 4.0 too? Is the connector on the wiring harness different?

 

[taylor0987]

Here's two posts from Doug904 about it: http://www.explorerforum.com/forums/showthread.php?t=65729&highlight=swap http://www.explorerforum.com/forums/showthread.php?t=123432&highlight=swap
in one of the posts he says injectors must be changed, while the other says the injectors can be re-used. From other stuff I've read it sounds like the Aerostar 4.0s were changed later than those in the ranger and x.

In response to your post Brooklyn Bay, The injector connector from 92 to 96 is the same and didn't change to the oval connectors/pencil style injectors until later. Having the same connector doesn't mean much--a couple of the 96 sensors have the same connector as the 92 but the 92 sensor needs to be swapped onto the 96 engine.

Navajos are mechanically identical to an Explorer Sport of the same model year so it is a 4.0. Ford's part listings show the 91-92 Explorer needing different injectors than the 96 Aerostar. I don't know if you have dealt with dealers and modified vehicles but so many of them will just look at their parts reference and tell me "ohhhh NO!!!! You can't swap a 96 motor into a 92. Would you like to order a rebuilt 92 motor? It will take only 4 months to get and cost $2000!"

I am asking here instead of the dealer because there are plenty of others who have done similar swaps and who are far more knowledgable about this kind of thing than most dealer techs or parts guys would know.

 

[BrooklynBay]

So far, I've only had experience with the 88, and 89 Aerostar with a 3.0, and a 93 Aerostar with a 4.0. According to what Doug said in one of those links, you could put a 96 into a 92, but not a 92 into a 96. The flywheel is different along with other changes. I would recommend sending Doug an email, or a personal message through this site. He said that he's done a lot of these swaps, and would be the best person to ask for advice. There is also another book that would be perfect for you. The wrecking yards use it. It's called the Hollander interchange manual. I don't own one, but I've seen it at these yards. It's a big binder with all kinds of interchange information.

 

[taylor0987]

Thanks, I just moved the old injectors over to the new engine, it took something like 15 minutes to do. I put the engine in today and just need to reinstall everything else.

 

[BrooklynBay]

I would hold onto the other set of injectors, and still find out if they could eventually be used. I did a search on EBay for that Hollander interchange manual, and saw a bunch of them. You could just call a wrecking yard that has the book too. It might also be a good idea to flush out the injectors when the engine is in use with a pressurized cleaning kit, and use new O-ring seals on them, so that they don't leak.