Fuel Rail Supply Tube: Removal

WARNING: This page is about a different car, the 2018 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: 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.

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: 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.

Drain the engine cooling system. Refer to: Cooling System Draining, Vacuum Filling and Bleeding .
Remove the air cleaner. Refer to: Air Cleaner .
Remove the fuel injection pump supply tube assembly. Refer to: Fuel Injection Pump Supply Tube Assembly .
Disconnect the coolant crossover-to-EGR (exhaust gas recirculation) cooler pipe quick release coupling. Refer to: Quick Release Coupling .

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Remove the coolant crossover-to-EGR (exhaust gas recirculation) cooler pipe bolts and then remove the coolant crossover-to-EGR (exhaust gas recirculation) cooler pipe.

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Remove and discard the O-ring seal from the coolant crossover-to-EGR (exhaust gas recirculation) cooler pipe.

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- Remove and discard the turbocharger coolant return tube bolt, then disconnect the turbocharger coolant return tube from the turbocharger.
- Disconnect the turbocharger coolant return tube from the coolant crossover and then remove the turbocharger coolant return tube.
  Use the General Equipment: Hose Clamp Remover/Installer
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NOTE: Special attention needs to be given to the sealing ports for the oil feed, the oil drain, and the coolant lines, on turbocharged engines. The sealing ports must be totally clean and free from O-ring residue, have no damage to the sealing surface and the lines to ensure that there are no leaks or repeat repairs.

NOTE: Inspect the turbocharger tube and the sealing surfaces. Ensure that the retaining bracket is not bent, check for square-ness of the retaining bracket to the O-ring area. Use brake cleaner and a nylon brush to clean. Do-not use a metal brush; damage to sealing area will result in leaks.

Remove and discard the turbocharger coolant return tube O-ring seal.

Material

: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

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Remove the oil fill cap. Remove the oil fill pipe bolt and then remove the oil fill pipe.

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Remove and discard the oil fill pipe O-ring seal.

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- Disconnect the cylinder No. 5 fuel injector electrical connector.
- Disconnect the engine wiring harness retainers from the front of the left valve cover.
- Disconnect the wiring harness retainer from the fuel rail supply tube bracket stud.
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Detach the wire harness retainers.

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Remove the wire harness retainer bolt, then detach the wire harness retainer.

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Detach the wire harness retainers, then disconnect the electrical connectors.

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NOTE: It may be necessary to unthread the engine sound shield retainers from the engine.

Remove the right engine sound shield retainers and then remove the right engine sound shield.

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Disconnect the fuel injector return hose retainer form the fuel rail supply tube.

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Remove the fuel rail supply tube bracket bolts and the fuel rail supply tube bracket stud bolt.

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Loosen and disconnect the fuel rail supply tube fittings at the injection pump.

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Detach the wiring harness retainer and the fuel injector fuel return line retainer from the left fuel rail.

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Loosen and disconnect the fuel rail supply tube fittings at the left fuel rail.

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Disconnect the wiring harness retainer from the right fuel rail.

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Loosen and disconnect the fuel rail supply tube fitting at the right fuel rail.

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

Remove and discard the fuel rail supply tube assembly.

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