Fuel Rail: Service and Repair
Fuel Rail
WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.
Special Tool(s)
Material(s)
Exploded View
Removal
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.
WARNING: Always disconnect the battery ground cable at the battery when working on an EVAP (Evaporative Emission) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
NOTE: A clean working environment is essential to prevent dirt or foreign material contamination.
1. Release the fuel system pressure, REFER to Fuel System Pressure Release .
2. Disconnect the battery ground cable, REFER to Battery Disconnect .
3. Remove the intake manifold, REFER to Intake Manifold .
4. NOTE: Use care when removing the fuel injection pump noise insulator. Spreading the openings will aid in removing the fuel injection pump noise insulator and reduce the risk of damage.
Remove the fuel injection pump noise insulator shield.
5. NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the fuel injection pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of fuel injection pump flare nut.
Remove the high pressure fuel tube.
1. Remove the high pressure fuel tube bracket bolts.
2. Loosen the high pressure fuel tube-to-fuel rail flare nut.
3. Loosen the high pressure fuel tube-to-fuel injection pump flare nut.
4. Remove and discard the high pressure fuel tube.
6. Detach the 2 fuel charge wire harness retainers from the fuel rail.
7. Remove the fuel rail insulator.
8. Release the coolant bypass hose from the retainer clip.
9. Disconnect the 4 fuel injector electrical connectors.
10. Disconnect the FRP (Fuel Rail Pressure) sensor electrical connector.
11. NOTICE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.
NOTE: Use compressed air and remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and injectors.
NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain in the cylinder heads and require the use of a Fuel Injector Remover tool to extract.
Remove the 4 bolts and remove the fuel rail.
12. Remove and discard the fuel injector clips.
13. Remove any of the fuel injectors that remained in the fuel rail.
14.
1. 307-005 (T59L-100-B).
2. 310-206.
15. Remove and discard the upper fuel injector O-ring seals and the upper fuel injector O-ring seal support rings.
16. NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.
NOTE: Do not use compressed air to clean the tip of the fuel injector.
NOTE: Do not use a brush to clean the tip of the fuel injector.
310-205.
Installation
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.
WARNING: Always disconnect the battery ground cable at the battery when working on an EVAP (Evaporative Emission) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
NOTE: A clean working environment is essential to prevent dirt or foreign material contamination.
1. NOTICE: Do not attempt to cut the lower Teflon(R) seal without first pulling it away from the fuel injector or damage to the injector may occur.
NOTE: Be very careful when removing the lower Teflon(R) seals, not to scratch, nick or gouge the fuel injectors.
Pull the lower Teflon(R) seal away from the injector with narrow tip pliers.
2. Carefully cut and discard the lower fuel injector Teflon(R) seals.
3. NOTICE: Once the Teflon(R) seal is installed on the Arbor, it should immediately be installed onto the fuel injector to avoid excessive expansion of the seal.
Using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon(R) seals off of the Arbor and into the groove on the fuel injectors.
1. 303-1567.
2. 310-207.
3. Make sure that new lower fuel injector Teflon(R) seals 9229 are installed.
4. 310-207.
4. NOTE: Make sure the Teflon(R) seal is fully seated in the groove on the fuel injector before sizing the seal.
NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon(R) seal expansion.
303-1507.
5. NOTICE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.
NOTE: Do not lubricate the new lower Teflon(R) fuel injector seals.
NOTE: Lubricate the upper fuel injector O-ring seals with Motorcraft(R) SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft(R) SAE 5W-20 Super Premium Motor Oil (Canada).
NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon(R) seal expansion.
Install the new upper fuel injector O-ring seal support rings and the new upper fuel injector O-ring seals.
6. Install the new fuel injector clips.
7. NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.
NOTE: The fuel rail pressure sensor must be replaced if it is removed from the fuel rail.
Install the fuel injectors into the fuel rails.
8. NOTE: Do not lubricate the new lower Teflon(R) fuel injector seals.
Install the fuel rail and the 4 bolts.
1. Push down on the fuel rail face above the injectors.
- Tighten to 25 Nm (18 lb-ft) in the sequence shown.
9. Connect the FRP (Fuel Rail Pressure) sensor electrical connector.
10. Connect the 4 fuel injector electrical connectors.
11. Attach the coolant bypass hose to the retainer clip.
12. Install the fuel rail insulator.
13. Attach the 2 fuel charge wire harness retainers to the fuel rail.
14. Position a new high-pressure fuel tube and hand start the 2 flare nuts in the following order.
1. Hand tighten the high pressure fuel tube-to-fuel rail flare nut.
2. Hand tighten the high pressure fuel tube-to-fuel injection pump flare nut.
15. Loosely install the high pressure fuel tube bracket bolts.
16. NOTE: Calculate the correct torque wrench setting for the following torque. REFER to Torque Wrench Adapter Formulas .
Tighten the high pressure fuel tube-to-fuel rail flare nut in the following 2 stages.
- Stage 1: Using a torque adapter, tighten to 15 Nm (133 lb-in).
- Stage 2: Tighten an additional 45 degrees.
17. NOTE: Calculate the correct torque wrench setting for the following torque. REFER to Torque Wrench Adapter Formulas .
Tighten the high pressure fuel tube-to-fuel injection pump flare nut in the following 2 stages.
- Stage 1: Using a torque adapter, tighten to 15 Nm (133 lb-in).
- Stage 2: Tighten an additional 45 degrees.
18. Tighten the high-pressure fuel tube bracket bolts.
- Tighten to 10 Nm (89 lb-in).
19. Install the fuel injection pump noise insulator shield.
20. Install the intake manifold, REFER to Intake Manifold .
21. Connect the battery ground cable, REFER to Battery Disconnect .
22. Pressurize the fuel system, REFER to Fuel System Pressure Release .