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Home >> Ford >> 2012 >> Explorer Limited, 3.5 8, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 91 (Fuel Charging System & Fuel Control System - 6.8L) >> Removal And Installation >> Fuel Rail >> Removal

Fuel Rail: Removal

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty and 2013 Ford F-450 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Do not smoke, carry lighted tobacco or have 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. Failure to follow these instructions may result in serious personal injury.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
NOTE: 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.
NOTE: 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 (ACL) outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  4. Disconnect the fuel supply tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
  5. Disconnect the Electronic Throttle Control (ETC) electrical connector.
  6. Disconnect the Throttle Position (TP) sensor electrical connector.
  7. Disconnect the 10 fuel injector electrical connectors.
  8. Detach the 2 main engine wiring harness retainers from the intake manifold and position the harness for access to remove the fuel rail.
  9. NOTE: When removing the fuel rail, leave the fuel injectors in the intake manifold. This will ease removal of the fuel rail.

    Remove the 6 bolts, the 10 fuel injector-to-fuel rail clips and separate the fuel rail from the injectors and remove the fuel rail.

    • To install, tighten to 10 Nm (89 lb-in).
  10. NOTE: Use specified service O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak.
    NOTE: Lubricate the new O-ring seals with clean engine oil prior to installation.

    Remove the fuel injectors from the intake manifold and discard the upper and lower fuel injector O-ring seals.

  11. To install, reverse the removal procedure.
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