Fuel Rail: Service and Repair

REMOVAL

WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Relieve the fuel pressure.
3. Partially drain the cooling system. For additional information, refer to Cooling System.







4. Remove the power steering reservoir bracket.
1 Remove the bolts.
2 Position the power steering reservoir bracket out of the way.







5. Remove the accelerator control splash shield.
1 Remove the bolts.
2 Remove the accelerator control splash shield.







6. Disconnect the fuel pressure regulator valve vacuum hose.
7. Disconnect the fuel lines.

CAUTION: After disconnecting, plug the fuel lines to prevent leakage.







8. Disconnect the eight ignition coil electrical connectors.







9. Disconnect the eight fuel injector electrical connectors.







10. Remove the brake booster bracket and tube.
1 Remove the nut.
2 Release and move the two hose clamps.
3 Remove the brake booster tube.







11. Remove the Positive Crankcase Ventilation (PCV) hose.







12. Disconnect the EGR connections:
^ (A) EGR valve to exhaust manifold tube upper fitting
^ (B) two differential pressure feedback transducer hoses
^ (C) EGR valve to exhaust manifold tube lower fitting

13. Remove the EGR tube.







14. Disconnect the EGR valve vacuum hose.







15. Disconnect the Vapor Management Valve (VMV) hose.







16. Remove the bolts and lift the fuel injection supply manifold and injectors upward, out of the intake manifold.







17. Remove the fuel injectors from the fuel injection supply manifold.







18. Inspect the two O-ring seals from each fuel injector. Install new O-ring seals as needed.

INSTALLATION
1. Install two O-ring seals to each fuel injector.

NOTE: Lubricate the new O-ring seals with clean engine oil, XO-10W30-QSP or DSP or equivalent meeting Ford specification WSS-M2C153-G to aid installation.

2. Install the fuel injectors into the fuel injection supply manifold.







3. Install the four bolts.







4. Connect the VMV hose.







5. Connect the EGR valve hose.
6. Position EGR tube on the engine.







7. Connect the EGR connections:
^ (A) two differential pressure feedback transducer hoses
^ (B) EGR valve to exhaust manifold tube upper fitting
^ (C) EGR valve to exhaust manifold tube lower fitting







8. Install the PCV hose.







9. Install the brake booster bracket and tube.
1 Install the brake booster tube.
2 Install the two hose clamps.
3 Install the nut.







10. Connect the eight fuel injector electrical connectors.







11. Connect the eight ignition coil electrical connectors.
12. Connect the fuel lines.







13. Connect the fuel pressure regulator valve vacuum hose.







14. Install the accelerator control splash shield.







15. Install the power steering reservoir bracket.
16. Connect the battery ground cable.
17. Fill the cooling system. For additional information, refer to Cooling System.