Fuel Rail Supply Tube: Removal

WARNING: This page is about a different car, the 2012 Ford Pickup, 2012 Ford F550 Super Duty, 2012 Ford F450 Super Duty, and 2012 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel openings to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.

WARNING: Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.

Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
Drain the cooling system. For additional information, refer to ENGINE COOLING - DIESEL ENGINE .
Remove the fuel injection pump supply tube assembly. For additional information, refer to FUEL INJECTION PUMP SUPPLY TUBE .
Remove the 2 coolant crossover-to-heater core pipe bolts.
- Disconnect the coolant crossover-to-heater core pipe quick connect fitting.
- Remove the coolant crossover-to-heater core pipe.
- Remove and discard the O-ring from the coolant crossover-to-heater core pipe.
  
  Fig 1: Locating Coolant Crossover-To-Heater Core Pipe Bolts
  Courtesy of FORD MOTOR CO.
Remove the Exhaust Gas Recirculation (EGR) valve inlet tube. For additional information, refer to Exhaust Gas Recirculation (EGR) Valve - Exploded View, 6.7L Diesel in ENGINE EMISSION CONTROL .

NOTE: Use a 3/8 inch Jiffy-tite quick line disconnect tool, such as Snap-on® LDTSP4 or equivalent, to disconnect the turbocharger coolant outlet tube.

Fig 2: Locating Turbocharger Coolant Outlet Tube

Courtesy of FORD MOTOR CO.

Disconnect the turbocharger coolant outlet tube from the turbocharger.
Disconnect and remove the turbocharger coolant return tube from the coolant crossover.
Remove the oil fill pipe bolt and the oil fill pipe.

Fig 3: Locating Oil Fill Pipe And Bolt
Courtesy of FORD MOTOR CO.
Disconnect the cylinder No. 5 fuel injector electrical connector.
- Disconnect the engine wiring harness retainer from the front of the LH valve cover.
  
  Fig 4: Locating Cylinder No. 5 Fuel Injector Electrical Connector And Engine Wiring Harness Retainer
  Courtesy of FORD MOTOR CO.
Disconnect the wiring harness retainer from the fuel rail supply tube bracket stud.

Fig 5: Locating Wiring Harness Retainer Of Fuel Rail Supply Tube Bracket Stud
Courtesy of FORD MOTOR CO.
Disconnect the 3 fuel injector return hose retainers form the fuel rail supply tube.

Fig 6: Locating Fuel Injector Return Hose Retainers Of Fuel Rail Supply Tube
Courtesy of FORD MOTOR CO.
Disconnect the fuel injector return hose retainer from the secondary fuel filter bracket.

Fig 7: Locating Fuel Injector Return Hose Retainer Of Secondary Fuel Filter Bracket
Courtesy of FORD MOTOR CO.

NOTE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components.

NOTE: The fuel rail supply tube assembly cannot be reused. Remove and discard the fuel rail supply tube assembly any time a fuel rail supply tube high-pressure fitting has been loosened.

Remove and discard the fuel rail supply tube assembly.
1. Remove the 4 fuel rail supply tube bracket bolts and the fuel rail supply tube bracket stud bolt.
2. Loosen the 2 fuel rail supply tube fittings at the injection pump.
3. Loosen the 3 fuel rail supply tube fittings at the LH fuel rail.
4. Loosen the fuel rail supply tube fitting at the RH fuel rail.