Fuel Rail: Service and Repair
REMOVALWARNING:
^ 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. USE CARE WHEN WORKING ON THE FUEL SYSTEM OR PERSONAL INJURY MAY OCCUR.
^ BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT POSSIBLE PERSONAL INJURY.
1. Remove the engine appearance cover.
2. Relieve the fuel pressure.
3. Remove the air cleaner outlet tube from the throttle body.
4. Disconnect the electrical connector from the fuel pressure sensor.
5. Disconnect the fuel pressure sensor vacuum hose.
NOTE: The fuel pressure sensor vacuum hose must be disconnected at the jumper connection, not at the sensor.
6. Disconnect the fuel line.
7. Remove the nuts and the engine appearance cover bracket.
8. Disconnect the eight fuel injector electrical connectors.
NOTE: RH side shown; LH side similar.
9. Remove the throttle body heater return hose from the retaining clip.
10. Disconnect the Camshaft Position (CMP) sensor.
11. Remove the air assist hose from both sides of the intake manifold and the Idle Air Control (IAC) valve.
NOTE: Do not use tools to remove the air assist hose fittings. Squeeze the fitting by hand to disconnect the air assist hose.
12. Remove the four bolts and the fuel injection supply manifold.
13. Remove the retaining clip and the fuel injectors from the fuel injection supply manifold.
14. Remove and discard the two O-ring seals from each fuel injector.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Install new O-ring seals.
NOTE: Lubricate new fuel injector O-ring seals with Super Premium SAE5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.