Direct Injection Fuel Rail: Removal

Release the fuel system pressure. Refer to: Fuel System Pressure Release .
Disconnect the battery. Refer to: Battery Disconnect and Connect .
Remove the air cleaner. Refer to: Air Cleaner .
Remove the intake manifold. Refer to: Intake Manifold .
Remove the high-pressure pump rear crash shield.

Courtesy of FORD MOTOR COMPANY
Disconnect the high-pressure pump electrical connector and move aside.

Courtesy of FORD MOTOR COMPANY
Disconnect the high-pressure pump fuel supply tube, detach the retainers and postion aside. Refer to: Spring Lock Couplings .

Courtesy of FORD MOTOR COMPANY
Remove the stud bolts and the high-pressure pump crash shield.

Courtesy of FORD MOTOR COMPANY
NOTE: When removing or installing the noise insulator, spreading the openings will reduce the risk of damage.

Remove the high-pressure pump insulator cover.

Courtesy of FORD MOTOR COMPANY
NOTE: Always wrap the fuel line connection with a towel before disconnecting it.
- Remove the high-pressure pump fuel tube retaining bracket bolt.
- Loosen the high-pressure fuel tube flare nuts, then disconnect, remove and discard the high-pressure fuel tube.
Courtesy of FORD MOTOR COMPANY
Disconnect the fuel injector wire harness electrical connector.

Courtesy of FORD MOTOR COMPANY
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. Wiggling the fuel injector and twisting the fuel injector by hand to break it loose may allow the fuel injector to be removed.
- 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 fuel injectors.
- Remove and discard the bolts, then remove the fuel rail.
Courtesy of FORD MOTOR COMPANY
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 fuel injector by hand to break it loose may allow the fuel 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.

Remove any of the fuel injectors that remained in the cylinder head. Install the special tool 310-206 below the lip on the upper fuel injector body as pictured. Push the adapter tool 310-206-01 all of the way down to grip the fuel injector tightly, in order to keep the tool from slipping off of the fuel injector.Use Special Service Tool: 307-005 (T59L-100-B) Slide Hammer., 310-206 Remover, Fuel Injector., 310-206-01 Adapter for 310-206.

Courtesy of FORD MOTOR COMPANY
Clean the fuel injector cylinder bores. Refer to: Fuel Injector Bore Cleaning .
Disconnect the electrical connectors and detach the fuel rail wire harness.

Courtesy of FORD MOTOR COMPANY
Remove the fuel injectors from the fuel rail.

Courtesy of FORD MOTOR COMPANY
Remove and discard the fuel injector clips.

Courtesy of FORD MOTOR COMPANY
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.

Courtesy of FORD MOTOR COMPANY
Inspect the components. Install new components as needed.

Courtesy of FORD MOTOR COMPANY
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 fuel injector may occur.
1. Pull the lower Teflon® seal away from the fuel injector.
2. Carefully cut and discard the lower fuel injector Teflon® seal.

Courtesy of FORD MOTOR COMPANY