Fuel Rail: Service and Repair

Fuel Injection Supply Manifold

REMOVAL

1. Perform Fuel System Pre-Service Procedures and Fuel Pressure Release procedure as outlined under Fuel Delivery And Air induction/Service And Repair.
2. Remove upper intake manifold.
3. Disconnect engine control sensor wiring from fuel injectors and position engine control sensor wiring out of way.
4. Disconnect vacuum line at fuel pressure regulator.
5. If required, remove fuel pressure regulator and fuel pressure relief valve from the fuel injection supply manifold.
6. Remove spring lock coupling retainer clip from fuel supply and return fittings.

NOTE: The following items should be noted when service to spring lock coupling is required:
^ Use specified tool or equivalent.
^ Inspect for missing or damaged O-rings.
^ Use the specified fuel resistant O-rings.
^ Lubricate the O-rings with clean engine oil XO-10W30-QSP or -DSP or equivalent meeting Ford specification ESE-M2C153-E.
^ Check to make sure that the fittings are locked.

7. Using Spring Lock Coupling Disconnect Tool D87L-9280-A (3/8 inch) or D87L-9280-B (1/2 inch) or equivalent, disconnect the fuel supply and return hoses from the fuel injection supply manifold.
8. Remove fuel injection supply manifold retaining bolts.

NOTE: It may be easier to remove fuel injectors with the fuel injection supply manifold as an assembly.

9. Carefully disengage fuel injection supply manifold with fuel injectors and remove fuel injection supply manifold and fuel injectors.
10. Remove fuel injectors from fuel injection supply manifold by rocking fuel injector from side-to-side while pulling up gently.

INSTALLATION

CAUTION: When installing fuel injection supply manifold, pay particular attention to proper O-ring seating to make sure that no fuel leaks exist or damage to vehicle may occur.

1. Install fuel injectors into fuel injection supply manifold as outlined.
2. Install fuel injection supply manifolds and retaining bolts while holding fuel injection supply manifold down. Tighten bolts to 8-12 Nm (71-106 lb in).
3. Install fuel supply and return hoses with spring lock couplings.
4. If removed, install fuel pressure relief valve and fuel pressure regulator onto the fuel injection supply manifold.
5. Connect vacuum line to fuel pressure regulator.
6. Connect battery ground cable .
7. With engine control sensor wiring disconnected, turn ignition switch to the RUN position several times to allow the fuel pump to pressurize the fuel system.
8. Using a clean paper towel and rubber gloves, check for leaks where the fuel injectors connect to the fuel injection supply manifold and intake manifold. If leaks are detected, service as required.
9. Connect fuel charging wiring to fuel injectors.
10. Install upper intake manifold.
11. Run vehicle at idle for two minutes.
12. Turn engine OFF and inspect for leaks.