Direct Injection Fuel Rail RH: Removal

WARNING: This page is about a different car, the 2021 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

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.

Release the fuel system pressure. Refer to: Fuel System Pressure Release .
Remove the intake manifold. Refer to: Intake Manifold .
Disconnect the ignition coil-on-plug electrical connectors.

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NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
1. Use compressed air to remove any foreign material from the ignition coil-on-plugs and surrounding area before removing the ignition coil-on-plugs.
2. Remove the bolts, then remove the ignition coil-on-plug.
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Disconnect the high-pressure fuel pump electrical connector.

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NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.

Release the retainer, then remove the fuel injection pump noise insulator.

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Detach the wiring harness retainer from high-pressure fuel line shield.

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Disconnect the fuel injector main harness electrical connector.

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Remove the high-pressure fuel line shield retainers, then remove high-pressure fuel line shield.

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Detach the wiring harness retainer, then disconnect the electrical connector.

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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 the high-pressure fuel tube flare nuts.

Remove the high-pressure fuel tube retainers. Disconnect the high-pressure fuel tube flare nuts, then remove and discard the high-pressure fuel tube.

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Remove the insulators.

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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 the high-pressure fuel tube flare nuts.

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

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Disconnect the fuel injector electrical connectors.

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NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.
1. Use compressed air and remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and injectors.
2. Remove the fuel rail bolts, then remove the fuel rail.
- 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. Gently wiggling the injector by hand to break it loose may allow the injector to be removed by hand.
- 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.
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Remove the fuel injectors from the fuel rail.

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Remove and discard the fuel injector clips.

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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. Gently wiggling the injector by hand to break it loose may allow the injector to be removed by hand.

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.

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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.
1. NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.
2. Using the special tool, clean the cylinder head fuel injector bores.
  Use Special Service Tool: 310-205 Fuel Injector Brush.
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1. Remove and discard the fuel injector O-ring seals.
2. NOTE: Note the correct orientation of the fuel injector support rings for 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.
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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.

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