Fuel Rail: Removal

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

WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.

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.

For exploded views, see fuel charging and controls - description and operation. Refer to: Fuel Charging and Controls - Component Location .
Release the fuel system pressure. Refer to: Fuel System Pressure Release .
Disconnect the battery. Refer to: Battery Disconnect and Connect .
Remove the intake manifold. Refer to: Intake Manifold .
Disconnect the fuel pump electrical connector.
NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.

Remove the fuel injection pump noise insulator.

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

Remove the following items:
1. Remove the high pressure fuel tube bracket bolts.
2. Loosen the high pressure fuel tube-to-fuel rail flare nut.
3. Loosen the high pressure fuel tube-to-fuel injection pump flare nut.
4. Remove and discard the high pressure fuel tube.
Detach the 2 fuel charge wire harness retainers from the fuel rail.
Remove the fuel rail insulator.
Release the coolant bypass hose from the retainer clip.
Disconnect the 4 fuel injector electrical connectors.
Disconnect the FRP sensor electrical connector.
NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.

NOTE: 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.

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.

Remove the bolts and the fuel rail.

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Remove any of the fuel injectors that remained in the fuel rail.

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Remove and discard the fuel injector clips.

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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: 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 O-ring seals and the fuel injector support rings.

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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.

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.

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