Removal and Installation

WARNING: This page is about a different car, the 2005 Ford Pickup. 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.

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.

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 air cleaner and air cleaner intake pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
Disconnect the fuel vapor quick connect fitting from the evaporative emission (EVAP) canister purge valve and position aside. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .

Fig 1: Disconnecting Fuel Vapor Quick Connect Fitting From Evaporative Emission Canister Purge Valve
Courtesy of FORD MOTOR CO.
Disconnect the heated positive crankcase ventilation (PCV) valve electrical connector.

Fig 2: Disconnecting Heated Positive Crankcase Ventilation (PCV) Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the PCV hose from the intake manifold and position aside.

Fig 3: Disconnecting PCV Hose From Intake Manifold
Courtesy of FORD MOTOR CO.
Disconnect the electronic throttle control electrical connector.

Fig 4: Disconnecting Electronic Throttle Control Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the throttle position (TP) sensor electrical connector.

Fig 5: Disconnecting Throttle Position Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the vacuum hose near the rear of the RH valve cover.

Fig 6: Disconnecting Vacuum Hose Near Rear Of RH Valve Cover
Courtesy of FORD MOTOR CO.
Disconnect the fuel rail pressure and temperature (FRPT) sensor electrical connector.
Disconnect the FRPT sensor vacuum hose.
Disconnect the 8 fuel injector electrical connectors.
Disconnect the spring lock couplings at the fuel rail. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Remove the 4 fuel rail bolts.
- To install, tighten to 10 Nm (89 lb-in).

CAUTION: When installing the fuel injectors, make sure that the injectors are fully engaged in the fuel injector cups.

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

NOTE: Install new O-rings seals on the fuel injectors.

Remove the fuel rail and injectors as an assembly.

NOTE: Lubricate the O-ring seal with clean engine oil.

If installing a new fuel rail, remove the 2 FRPT bolts and remove the FRPT sensor.
- To install, tighten to 4 Nm (35 lb-in).
- Inspect the O-ring seal and install a new seal if necessary.
To install, reverse the removal procedure.