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Home >> Ford >> 2017 >> Fusion Titanium, AWD >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls - Fuel Charging And Controls - 2.0L ECOBOOST (184KW/250PS) - Mi4 >> Removal And Installation >> Fuel Rail >> Removal

Fuel Rail: Removal

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.
  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. Remove the upper air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
  5. Detach the brake vacuum line retainer and position the brake vacuum line out of the way.
    GFD193380Courtesy of FORD MOTOR COMPANY
  6. Disconnect the high-pressure fuel pump electrical connector.
    GFD193381Courtesy of FORD MOTOR COMPANY
  7. 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.

    GFD193382Courtesy of FORD MOTOR COMPANY
  8. Remove the evaporative emission canister purge valve bracket nuts and then move the evaporative emission canister purge valve out of the way.
    GFD193383Courtesy of FORD MOTOR COMPANY
  9. Remove the high-pressure fuel tube nut and bolt.
    GFD193384Courtesy of FORD MOTOR COMPANY
  10. 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.

    Loosen the high-pressure fuel tube flare nuts, disconnect, remove and discard the high-pressure fuel tube.

    GFD193385Courtesy of FORD MOTOR COMPANY
  11. Disconnect the electrical connector retainer from the fuel rail tab.
    GFD193386Courtesy of FORD MOTOR COMPANY
    • Disconnect the FRP sensor electrical connector.

    • Remove the fuel rail insulator and then disconnect the fuel injector electrical connectors.

    GFD193387Courtesy of FORD MOTOR COMPANY
  13. 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, 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 head and require the use of a Fuel Injector Remover tool to extract. Wiggling the injector by hand to break it loose may allow the injector to be removed by hand.

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

    GFD193388Courtesy of FORD MOTOR COMPANY
  14. Remove the fuel injectors from the fuel rail.
    GFD193389Courtesy of FORD MOTOR COMPANY
  15. Remove and discard the fuel injector clips.
    GFD193390Courtesy of FORD MOTOR COMPANY
  16. 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 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.

    GFD193391Courtesy of FORD MOTOR COMPANY
  17. 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.
    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.

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

    GFD193392Courtesy of FORD MOTOR COMPANY
  18. NOTE: Note the correct orientation of the fuel injector support rings, to insure the correct installation of the new fuel injector support rings.

    • Remove and discard the fuel injector O-rings.

    • Remove and discard the fuel injector support rings.

    GFD193393Courtesy of FORD MOTOR COMPANY
  19. 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, remove and discard the lower fuel injector Teflon ® seals.

GFD192990Courtesy of FORD MOTOR COMPANY
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