Removal and Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: 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 can be ignited resulting in possible personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions may result in personal injury.

Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Remove the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
Remove the air cleaner and the air cleaner outlet tube. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
Disconnect the fuel tube spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Disconnect the fuel rail pressure (FRP) sensor electrical connector and vacuum hose.

Fig 1: Disconnecting Fuel Rail Pressure (FRP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the ten fuel injector electrical connectors.

Fig 2: Identifying Fuel Injector Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the positive crankcase ventilation (PCV) valve electrical connector and the tube from the RH valve cover.

Fig 3: Disconnecting Positive Crankcase Ventilation (PCV) Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the retaining nut and position the transmission fluid and indicator tube aside.

Fig 4: Identifying Transmission Fluid Level Indicator Tube And Retaining Nut
Courtesy of FORD MOTOR CO.
Remove the retainers from the fuel charging wiring harness and position the wiring harness away from the fuel injection supply manifold.

Fig 5: Removing Retainers From Fuel Charging Wiring Harness
Courtesy of FORD MOTOR CO.
Remove the fuel injection supply manifold support bracket bolts.

Fig 6: Removing Fuel Injection Supply Manifold Support Bracket Bolts
Courtesy of FORD MOTOR CO.

NOTE: Remove the fuel injection supply manifold and the fuel injectors as an assembly.

Fig 7: Removing Fuel Injection Supply Manifold

Courtesy of FORD MOTOR CO.

Remove the four retaining bolts and the fuel injection supply manifold.
Remove the fuel injectors from the fuel injection supply manifold.

Fig 8: Removing Fuel Injectors From Fuel Injection Supply Manifold
Courtesy of FORD MOTOR CO.
Remove and discard the O-ring seals from each fuel injector.

Fig 9: Identifying Fuel Injector O-Ring Seals
Courtesy of FORD MOTOR CO.

CAUTION: Check for fuel leakage after installation is complete.

NOTE: Be sure the fuel injectors and the fuel injection supply manifold are fully seated.

NOTE: Lubricate the new fuel injector O-ring seals with clean motor oil.

To install, reverse the removal procedure.