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Home >> Ford >> 2018 >> Fusion Platinum, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 140 (Engine Controls - Fuel Charging And Controls - 2.7L ECOBOOST (238KW/324PS)) >> Removal And Installation >> Fuel Rail >> Removal

Fuel Rail: Removal

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Both fuel rails 

  1. Release the fuel system pressure. Refer to: Fuel System Pressure Release .
  2. Remove the air cleaner. Refer to: Air Cleaner .
  3. Disconnect the battery. Refer to: Battery Disconnect and Connect .
  4. Remove the intake manifold. Refer to: Intake Manifold .
  5. Loosen the CAC intake lower pipe RH clamp.
    G00578781Courtesy of FORD MOTOR COMPANY
  6. Loosen the CAC intake upper pipe RH clamp.
    G00578782Courtesy of FORD MOTOR COMPANY
    1. Disconnect the EVAP canister purge valve quick release coupling. Refer to: Quick Release Coupling .
    2. Detach the retainer and position the EVAP canister purge valve tube aside.
      G00578783Courtesy of FORD MOTOR COMPANY
  8. Detach the coolant hose from the starter motor bracket.
    G00578784Courtesy of FORD MOTOR COMPANY
    1. Remove the bolt.
    2. Disconnect the bypass valve electrical connector and remove the CAC intake pipe RH.
      G00578785Courtesy of FORD MOTOR COMPANY
  10. Remove the fuel injector noise insulator.
    G00578786Courtesy of FORD MOTOR COMPANY
  11. NOTE: When removing or installing the high-pressure fuel pump noise insulator, spreading the openings will reduce the risk of damage.

    Remove the high-pressure fuel pump noise insulator.

    GFD193432Courtesy of FORD MOTOR COMPANY
  12. NOTE: To release the fuel pressure in the fuel rail-to-fuel rail high-pressure fuel tube, wrap the fuel rail-to-fuel rail high-pressure fuel tube flare nuts with a shop towel to absorb any residual fuel pressure during the loosening of the fuel rail-to-fuel rail high-pressure fuel tube flare nuts.

    Disconnect the fuel rail-to-fuel rail high-pressure fuel tube flare nuts, then remove and discard the fuel rail-to-fuel rail high-pressure fuel tube.

    GFD193433Courtesy of FORD MOTOR COMPANY

    Left fuel rail 

  13. Detach the wiring harness retainer.
    GFD193434Courtesy of FORD MOTOR COMPANY
  14. NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.
    NOTE: The isolator on the bottom of the fuel injector may fall off during removal. Look for any loose pieces and remove them. If this occurs replace the fuel injector.
    NOTE: Use compressed air and remove any dirt or foreign material from the cylinder head, the engine block and the general surrounding area of the fuel rail and the fuel injectors.
    NOTE: When removing the fuel rails, the fuel injectors may remain in the cylinder heads and require the use of a Fuel Injector Remover tool to extract. Wiggling the fuel injector by hand to break it loose may allow the injector to be removed by hand.
    NOTE: Should any of the fuel injectors remain in the head, then the fuel injector electrical connectors will need to be disconnected as the fuel rail is being removed.

    Remove the fuel rail bolts and then remove the fuel rail.

    GFD193435Courtesy of FORD MOTOR COMPANY
  15. Disconnect the fuel injector electrical connectors.
    GFD192985Courtesy of FORD MOTOR COMPANY
  16. NOTE: The inlet stopper, the fuel injector O-ring seals and the fuel injector support rings may remain in the fuel rail, be sure to check and remove them along with any debris found in the fuel rail.

    Remove the fuel injectors from the fuel rail.

    GFD192986Courtesy of FORD MOTOR COMPANY

    Right fuel rail 

  17. NOTE: To release the fuel pressure in the high-pressure fuel tube, wrap the high-pressure fuel tube flare nuts with a shop towel to absorb any residual fuel pressure during the loosening of high-pressure fuel tube flare nuts.

    Disconnect the high-pressure fuel pump-to-fuel rail high-pressure fuel tube flare nuts, then remove and discard the high-pressure fuel pump-to-fuel rail high-pressure fuel tube.

    GFD193436Courtesy of FORD MOTOR COMPANY
  18. Detach the wiring harness retainer.
    GFD193437Courtesy of FORD MOTOR COMPANY
  19. NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.
    NOTE: The isolator on the bottom of the fuel injector may fall off during removal. Look for any loose pieces and remove them. If this occurs replace the fuel injector.
    NOTE: Use compressed air and remove any dirt or foreign material from the cylinder head, the engine block and the general surrounding area of the fuel rail and the fuel injectors.
    NOTE: When removing the fuel rails, the fuel injectors may remain in the cylinder heads and require the use of a Fuel Injector Remover tool to extract. Wiggling the fuel injector by hand to break it loose may allow the injector to be removed by hand.
    NOTE: Should any of the fuel injectors remain in the head, then the fuel injector electrical connectors will need to be disconnected as the fuel rail is being removed.

    Remove the fuel rail bolts and then remove the fuel rail.

    GFD193438Courtesy of FORD MOTOR COMPANY
  20. Disconnect the fuel injector electrical connectors.
    GFD193439Courtesy of FORD MOTOR COMPANY
  21. NOTE: The inlet stopper, the fuel injector O-ring seals and the fuel injector support rings may remain in the fuel rail, be sure to check and remove them along with any debris found in the fuel rail.

    Remove the fuel injectors from the fuel rail.

    GFD193440Courtesy of FORD MOTOR COMPANY

    Both fuel rails 

  22. Remove and discard the fuel injector clips.
    GFD192987Courtesy of FORD MOTOR COMPANY
  23. NOTE: Use minimal force to remove the fuel injectors that remained in the cylinder head with the Fuel Injector Remover tool or damage to the fuel injector assembly may occur. Wiggling the injector by hand to break it loose may allow the fuel injector to be removed by hand.

    Using the special tools, remove any of the fuel injectors that remained in the cylinder head.

    Use Special Service Tool: 307-005 (T59L-100-B) Slide Hammer, 310-206 Remover, Fuel Injector.

    GFD193441Courtesy of FORD MOTOR COMPANY
  24. NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, the engine block and the general surrounding area of the fuel rails and the fuel injectors.
    NOTE: Do not use compressed air to clean the tip of the fuel injector.
    NOTE: Do not use a brush to clean the tip of the fuel injector.

    Using the special tool, clean the cylinder head fuel injector bores.

    Use Special Service Tool: 310-205 Fuel Injector Brush.

    GFD193442Courtesy of FORD MOTOR COMPANY
    1. Remove and discard the fuel injector O-ring seals.
    2. NOTE: Note the correct orientation of the fuel injector support rings, for the correct installation of the new fuel injector support rings.

      Remove and discard the fuel injector support rings.

    3. Inspect the inlet stopper, if it is damaged or comes off then discard the inlet stopper. The inlet stopper is not needed for proper function. Ensure that any debris from the inlet stopper are removed. If the inlet stopper is intact and undamaged do not remove the inlet stopper from the fuel injector.
    GFD192989Courtesy of FORD MOTOR COMPANY
  26. NOTE: Use care when removing the lower Teflon ® seals, not to scratch, nick or gouge the fuel injector.
    NOTE: Do not attempt to cut the lower Teflon ® seal without first pulling it away from the fuel injector or damage to the injector may occur.

    1. Pull the lower Teflon ® seal away from the injector.
    2. Carefully cut and discard the lower fuel injector Teflon ® seal.

    GFD192990Courtesy of FORD MOTOR COMPANY
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