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Home >> Ford >> 2021 >> Explorer Limited Hybrid, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 35 (Fuel Charging And Controls - 2.3L ECOBOOST (201KW/273PS)) >> Removal And Installation >> Fuel Rail >> Removal

Fuel Rail: Removal

WARNING: This page is about a different variant/trim than selected.
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.
  1. Release the fuel system pressure. Refer to: Fuel System Pressure Release .
  2. Disconnect the battery. Refer to: Battery Disconnect and Connect .
  3. Remove the intake manifold. Refer to: Intake Manifold .
  4. Disconnect the high-pressure fuel pump electrical connector and the sensor connector.
    GFD513198Courtesy of FORD MOTOR COMPANY
  5. 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.

    GFD513199Courtesy of FORD MOTOR COMPANY
  6. Disconnect the electrical connector, then detach the wiring harness retainers and move out of the way.
    GFD513200Courtesy of FORD MOTOR COMPANY
  7. Remove the nuts, then remove the bracket.
    GFD513201Courtesy of FORD MOTOR COMPANY
  8. NOTE: To release the fuel pressure in the high-pressure fuel tube, wrap the high-pressure fuel pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of high-pressure fuel pump flare nut.

    Remove the high-pressure fuel tube bracket bolt and studbolt. Loosen the high-pressure fuel tube flare nuts, then disconnect, remove and discard the high-pressure fuel tube.

    GFD513202Courtesy of FORD MOTOR COMPANY
  9. NOTE: An enhanced hexalobular or torx plus bit must be used.

    Remove the bolt, then remove the shield.

    GFD513203Courtesy of FORD MOTOR COMPANY
    • Detach the wire harness retainers from the fuel rail.

    • Remove the fuel rail insulator.

    GFD513204Courtesy of FORD MOTOR COMPANY
    • Disconnect the wire harness retainer from the fuel rail.

    • Disconnect the fuel rail pressure sensor electrical connector.

    • Move the fuel rail wire harness out of the way.

    GFD513205Courtesy of FORD MOTOR COMPANY
  12. NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.
    NOTE: When removing the fuel rails, the fuel injectors may remain in the cylinder head and require the use of a Fuel Injector Remover tool to extract. Wiggling the injector and twisting the injector by hand to break it loose may allow the injector to be removed.

    • Use compressed air to remove any dirt or foreign material from the cylinder head, block and the general surrounding area of the fuel rail and the injectors.

    • Remove and discard the bolts, then remove the fuel rail.

    GFD513206Courtesy of FORD MOTOR COMPANY
  13. Remove the fuel injectors from the fuel rail.
    GFD513207Courtesy of FORD MOTOR COMPANY
  14. Remove and discard the fuel injector clips.
    GFD513208Courtesy of FORD MOTOR COMPANY
  15. NOTE: Use minimal force to remove the fuel injectors with the Fuel Injector Remover tool or damage to the fuel injector assembly may occur. Wiggling the injector and twisting by hand to break it loose may allow the injector to be removed.
    NOTE: Commercially available OTC 5028 8-1/2" long slide hammer may be substituted for 307-005 where there are clearance concerns.

    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.

    GFD513209Courtesy of FORD MOTOR COMPANY
  16. 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.

    • 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 injectors.

    • Using the special tool, clean the cylinder head fuel injector bores. Use Special Service Tool: 310-205 Fuel Injector Brush.

    GFD513210Courtesy of FORD MOTOR COMPANY
  17. NOTE: Note the correct orientation of the fuel injector support rings for correct installation.

    Remove and discard the fuel injector O-rings. Remove and discard the fuel injector support rings.

    GFD513211Courtesy of FORD MOTOR COMPANY
  18. NOTE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.
    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.

GFD513212Courtesy of FORD MOTOR COMPANY
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