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Home >> Ford >> 2021 >> Bronco Base, 2D Utility, 2.3L Eng VIN H, Part Time T/Case Control, Automatic Trans >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Charging And Controls - 2.3L ECOBOOST (199KW/270PS) >> Removal And Installation >> Fuel Rail >> Removal

Fuel Rail: Removal

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 negative cable. Refer to: Battery Disconnect and Connect .
  3. Remove the intake manifold. Refer to: Intake Manifold .
    1. Detach the wiring harness retainer from the rear engine lift eye.
    2. Detach the wiring harness retainers and position aside.
    GFD624248Courtesy of FORD MOTOR COMPANY
  5. Release the tabs and remove the upper plastic and the foam high-pressure fuel pump cover.
    GFD625337Courtesy of FORD MOTOR COMPANY
  6. Remove the lower plastic and the foam high-pressure fuel pump cover retainer and position the fuel tube up.
    GFD625338Courtesy of FORD MOTOR COMPANY
  7. Using a knife, cut the lower plastic high-pressure fuel pump cover at the two positions shown, then remove the lower plastic high-pressure fuel pump cover. Use the General Equipment: Knife
    GFD625339Courtesy of FORD MOTOR COMPANY
    1. Remove the lower foam high-pressure fuel pump cover retainer.
    2. Using a knife, cut the lower foam high-pressure fuel pump cover at the position shown and remove. Use the General Equipment: Knife
    GFD624252Courtesy of FORD MOTOR COMPANY
  9. Position the fuel tube down.
    GFD624253Courtesy of FORD MOTOR COMPANY
  10. Remove the bolts and the high-pressure fuel pump bracket.
    GFD624254Courtesy of FORD MOTOR COMPANY
  11. NOTE: When removing the high-pressure fuel pump noise insulator, spreading the openings will reduce the risk of damage.

    Remove the high-pressure fuel pump noise insulator.

    GFD624255Courtesy of FORD MOTOR COMPANY
  12. Disconnect the electrical connector, then detach the wiring harness retainers and move the wire harness out of the way.
    GFD625340Courtesy of FORD MOTOR COMPANY
  13. 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 bolts. Loosen the high-pressure fuel tube flare nuts, then disconnect, remove and discard the high-pressure fuel tube.

    GFD625341Courtesy of FORD MOTOR COMPANY
  14. Remove the bolts, then remove the shield.
    GFD625342Courtesy of FORD MOTOR COMPANY
    1. Detach the wire harness retainers from the fuel rail.
    2. Remove the fuel rail insulator.
    GFD625343Courtesy of FORD MOTOR COMPANY
    1. Disconnect the wire harness retainer from the fuel rail.
    2. Disconnect the fuel rail pressure sensor electrical connector.
    3. Move the fuel rail wire harness out of the way.
    GFD625344Courtesy of FORD MOTOR COMPANY
  17. 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.

    1. Use compressed air to remove any dirt or foreign material from the cylinder head, the engine block and the general surrounding area of the fuel rail and the injectors.
    2. Remove and discard the bolts, then remove the fuel rail.

    GFD625345Courtesy of FORD MOTOR COMPANY
  18. Remove the fuel injectors from the fuel rail.
    GFD625346Courtesy of FORD MOTOR COMPANY
  19. Remove and discard the fuel injector clips.
    GFD625347Courtesy of FORD MOTOR COMPANY
  20. NOTE: Use minimal force to remove the fuel injectors with the Fuel Injector Remover tool or damage to the fuel injector assembly may occur.
    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. Wiggling the injector and twisting by hand to break it loose may allow the injector to be removed. Use Special Service Tool: 307-005 (T59L-100-B) Slide Hammer., 310-206 Remover, Fuel Injector.

    GFD625348Courtesy of FORD MOTOR COMPANY
  21. 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. 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.
    2. Using the special tool, clean the cylinder head fuel injector bores. Use Special Service Tool: 310-205 Fuel Injector Brush.

    GFD625349Courtesy of FORD MOTOR COMPANY
  22. 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.

    GFD625350Courtesy of FORD MOTOR COMPANY
  23. 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.

GFD625044Courtesy of FORD MOTOR COMPANY
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