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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 907 (Fuel System & Engine Controls -- 5.4L (3V) -- F250-F550 Super Duty) >> Removal And Installation >> Fuel Rail >> Removal and Installation

Removal and Installation

WARNING: This page is about a different car, the 2005 Ford Pickup and 2005 Ford Cab & Chassis. 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 may be ignited. Failure to follow these instructions may result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. 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.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.
CAUTION: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes.
CAUTION: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube.
  1. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION - GASOLINE AND DIESEL .
  2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Remove the air cleaner inlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  4. Disconnect the mass air flow (MAF) sensor electrical connector and position the wiring harness aside.
  5. Disconnect the brake booster vacuum hose.
  6. Disconnect the quick connect couplings and remove the positive crankcase ventilation (PCV) tube. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION - GASOLINE AND DIESEL .
  7. Disconnect the quick connect couplings and remove the crankcase ventilation tube. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION - GASOLINE AND DIESEL .
  8. Disconnect the fuel supply tube spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION - GASOLINE AND DIESEL .
  9. Disconnect the fuel rail pressure and temperature sensor electrical and vacuum connectors.
  10. Disconnect the electronic throttle control electrical connector.
    Fig 1: Disconnecting Electronic Throttle Control Electrical Connector
    G03982142Courtesy of FORD MOTOR CO.
  11. Disconnect the throttle position (TP) sensor electrical connector.
    Fig 2: Disconnecting Throttle Position Sensor Electrical Connector
    G03982143Courtesy of FORD MOTOR CO.
  12. Disconnect the heated PCV intake fitting electrical connector.
    Fig 3: Disconnecting Heated PCV Intake Fitting Electrical Connector
    G03922230Courtesy of FORD MOTOR CO.
    13. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
  13. Remove the 2 bolts and the fuel rail pressure and temperature sensor.
    • Discard the O-ring seal.
    • To install, tighten to 4 Nm (35 lb-in).
  14. Disconnect the 8 fuel injector electrical connectors.
  15. Remove the 8 fuel injector-to-fuel rail locking clips.
    16. NOTE: When removing the fuel rail, leave the fuel injectors in the intake manifold. This will make removal of the fuel rail easier.
  16. Remove the 4 fuel rail bolts and the fuel rail.
    • To install, tighten to 10 Nm (89 lb-in).
    17. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals. Lubricate the O-ring seals with clean engine oil prior to installation.
  17. Remove the fuel injectors and the fuel injector O-ring seals.
    • Discard the O-ring seals.
      Fig 4: Locating Fuel Injector O-Ring Seals
      G03885875Courtesy of FORD MOTOR CO.
  18. To install, reverse the removal procedure.
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