Fuel Rail - Removal and Installation

Special Service Tools / General Equipment

	303-1567 Size, Teflon Seal TKIT-2010C-FLM
	307-005 (T59L-100-B) Slide Hammer
	310-205 Fuel Injector Brush
	310-206 Puller, Fuel Injector TKIT-2009A-FLM
	310-206-01 Adapter for 310-206
	310-207 Installer, Fuel Injector Seal Assembly TKIT-2009A-FLM

Removal

1. 1
   Release the fuel system pressure.
   Refer to: Fuel System Pressure Release (310-00A Fuel System — General Information — 1.5 L EcoBoost (118 kW/160 L PS) — I4, General Procedures).
2. 2
   Disconnect the battery.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
3. 3
   Remove the spark plug coils.
   Refer to: Spark Plug Coil (303-07A Engine Ignition System - 1.5 L EcoBoost (118kW/160 L PS) - I4, Removal and Installation).
4. 4
   Disconnect the wiring harness retainers and disconnect the FRP sensor electrical connector.

   

5. 5

   NOTICE: To relieve the fuel pressure in the high-pressure fuel system, wrap the high-pressure fuel pump fuel line nut with a shop towel to absorb any residual fuel pressure while loosening the high-pressure fuel pump fuel line nut.

   Disconnect the high-pressure fuel tube flare nuts. Remove and discard the high-pressure fuel tube.

   

6. 6

   NOTICE: Pull the fuel rail straight out along the fuel injector axis, otherwise the fuel injectors may be damaged.

   Disconnect the main fuel injector wiring harness electrical connector, remove the fuel rail bolts, then remove the fuel rail.

   

7. 7
   Disconnect the fuel injector electrical connectors, then remove the fuel injectors from the fuel rail.

   

8. 8

   NOTICE: Use minimum force to remove fuel injectors that remain in the cylinder head with the Fuel Injector Remover tool, or damage to the fuel injector assembly may occur. Rocking the injector by hand to disconnect it may remove the injector manually.

   Remove any fuel injectors that remain in the cylinder head. Install the special tool 310-206 under the edge of the fuel injector upper body, as shown in the illustration. Push the adapter tool 310-206-01 fully down to firmly grip the fuel injector and keep the tool from slipping off the fuel injector.
   Use the special service tools: 307-005 (T59L-100-B) Slide Hammer, 310-206 Puller, Fuel Injector, 310-206-01 Adapter for 310-206.

   

9. 9
   Remove and discard the fuel injector clips.

   

10. 10

    NOTICE: Do not use compressed air to clean the fuel injector tip.

    NOTICE: Do not use a brush to clean the fuel injector tip.

    Using the special tool, clean the fuel injector bores in the cylinder head.
    Use the special service tool: 310-205 Fuel Injector Brush.

    

Installation

1. 1
   • Remove and discard the fuel injector O-rings.

   • Remove and discard the fuel injector backup rings.

   

2. 2

   NOTICE: Use care when removing the lower Teflon® seals to avoid scratching, nicking or gouging the fuel injectors.

   NOTICE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector, otherwise damage to the injector may occur.

   1. Pull the lower Teflon® seal off the injector using narrow-tip pliers.

   2. Carefully cut, remove and discard the lower fuel injector Teflon® seals.

   

3. 3

   NOTICE: Do not lubricate the new lower Teflon® fuel injector seals.

   1. Install the mandrel (part of the fuel injector seal installer) onto the fuel injector tips.
      Use the special service tool: 310-207 Installer, Fuel Injector Seal Assembly.

   2. NOTICE: After installing the Teflon® seal on the Teflon® seal guide, install it on the fuel injector immediately to prevent excessive expansion of the Teflon® seal.

      Install the new Teflon® seals onto the mandrel using the pusher (part of the fuel injector seal installer). Slide the Teflon® seals along the axis.

   3. Using the pusher, slide the Teflon® seals along the Teflon® seal guide and into the groove on the fuel injectors.
      Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.

   4. Remove the special tools.

   

4. 4

   NOTICE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to expansion of the Teflon® seal.

   1. Massage and warm the Teflon® seal with your fingers before installing the Teflon® seal sizing tool. This will help in installing the Teflon® seal sizing tool.

   2. Position the Teflon® seal sizing tool with the large opening facing the Teflon® seal. Press and turn the Teflon® seal sizing tool 180 degrees.
      Use special service tool: 303-1567 Teflon® Seal Sizer.

   3. After installing the Teflon® seal sizing tool, check and make sure the Teflon® seal is in the sizing portion of the Teflon® seal sizing tool.

   4. After one minute, turn the Teflon® seal sizing tool back 180 degrees and remove it.

   

5. 5

   NOTICE: Use new fuel injector O-rings made of special fuel-resistant material. Using standard O-rings may cause a fuel system leak. Do not reuse O-rings.

   NOTICE: Do not lubricate the new lower Teflon® fuel injector seals.

   
   

   • Install the new fuel injector backup rings, noting their orientation from removal.

   • Install the new fuel injector O-rings and lubricate them with clean engine oil.

   

6. 6
   Install the new fuel injector clips.

   

7. 7

   NOTICE: The FRP sensor must only be replaced if it has been removed from the fuel rail.

   Install the fuel injectors to the fuel rail, then connect the fuel injector electrical connectors.
   Refer to: Fuel Rail Pressure (FRP) Sensor (303-14A Electronic Engine Controls — 1.5 L EcoBoost (118 kW/160 L PS) — I4, Removal and Installation).

   

8. 8

   NOTICE: Do not lubricate the new lower Teflon® fuel injector seals.

   • Install the fuel rail, press the fuel rail down over the injectors. Install and tighten the fuel rail bolts in the sequence shown.
     Torque: 17 lb-ft (23 N·m)

   • Connect the fuel injector main wiring harness electrical connector.

   

9. 9

   NOTICE: Make sure a new high-pressure fuel line is installed.

   Tighten the high-pressure fuel line flare nuts in the following 3 steps.
   Torque:
   Step 1: 15 lb-ft (21 N·m)
   Step 2: Wait 5 minutes.
   Step 3: 15 lb-ft (21 N·m)

   

10. 10
    Attach the wiring harness clips and connect the FRP sensor electrical connector.

    

11. 11
    Install the ignition coil to the spark plug.
    Refer to: Spark Plug Ignition Coil (303-07A Engine Ignition System — 1.5 L EcoBoost (118 kW/160 L PS) — I4, Removal and Installation).
12. 12
    Connect the battery.
    Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
13. 13
    Build fuel system pressure.
    Refer to: Fuel System Pressure Release (310-00A Fuel System — General Information — 1.5 L EcoBoost (118 kW/160 L PS) — I4, General Procedures).