Fuel Rail: Service and Repair

Fuel Pressure Gauge:

Special Tools Desired

REMOVAL
1. Disconnect the battery ground cable.

WARNING:
- DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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, RESULTING IN POSSIBLE PERSONAL INJURY.
- FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN ENGINE IS NOT RUNNING.
- BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED.

NOTE: Before relieving the fuel pressure, make sure the ignition switch is in the OFF position.

2. Perform the fuel pressure release procedure.







3. Disconnect the crankshaft position sensor electrical connector.







4. Disconnect the two main engine harness electrical connectors above the RH front wheel well.







5. Disconnect the four fuel injector electrical connectors.







6. Disconnect the fuel pressure sensor electrical connector.







7. Disconnect the camshaft position sensor electrical connector.







8. Grasp the plastic wiring harness routing rail and pull upward separating it from the fuel injection supply manifold. Position the harness aside.
9. Use Disconnect Tool to disconnect the fuel inlet line to the fuel injection supply manifold. Unclip fuel inlet line from the fuel line support bracket.







10. Use Disconnect Tool to disconnect the fuel supply line from the fuel injection supply manifold.







11. Remove the two fuel injection supply manifold bolts.
12. Carefully disengage the fuel injection supply manifold from the fuel injectors and remove the manifold.

CAUTION: The fuel injection supply manifold and the fuel injectors must be handled with extreme care to prevent damage to the sealing areas and sensitive fuel metering orifices.

INSTALLATION
1. Position the fuel injection supply manifold on top of the fuel injectors and push down to ensure all fuel injector O-ring seals are seated in the fuel injection supply manifold cups and the Intake Manifold Runner Control (IMRC) assembly.

NOTE: Lubricate the fuel injector O-rings with 5W30 engine oil meeting Ford specification WSS-M2C153-G or equivalent prior to installing the fuel injection supply manifold.







2. Install the two fuel injection supply manifold bolts.
3. Connect the fuel return line to the fuel injection supply manifold.
4. Connect the fuel inlet line to the fuel injection supply manifold.
5. Clip the fuel supply line into the fuel line support bracket.







6. Position the wiring harness into place.
- Grasp plastic wiring harness routing rail and slide it back onto the fuel injection supply manifold.







7. Connect the camshaft position sensor electrical connector.







8. Connect the fuel pressure sensor electrical connector.







9. Connect the four fuel injector electrical connectors.







10. Connect the two main harness electrical connectors.







11. Connect the crankshaft position sensor electrical connector.
12. Connect the battery ground cable.
13. Start the engine and let it run for two minutes. Turn the engine off and inspect it for fuel leaks.