Ford 5W7Z-9F792-AC
Fuel Rail

Safety during fuel rail servicing requires personnel to stay away from smoking or open fire sources that exist near fuel components because dangerous highly flammable mixtures exist. A safe service practice includes fuel pressure reduction followed by fuel tube disconnection to ensure spraying accidents do not occur and battery ground cable disconnection is necessary when maintaining EVAP or fuel system components. Engine personnel should remove all fuel residue from the engine section because any ignition risk needs to be eliminated before starting the engine. Vehicle setup begins with deactivating fire suppression when systems permit followed by hoisting the vehicle at NEUTRAL position. Begin by lowering fuel system pressure and removing the buckle grounded to the battery before taking off the fuel tube at the fuel rail. Erase all connections related to the Throttle Body (TB) and also remove the EGR system module tube as well as the brake booster vacuum hose from the TB spacer along with the EVAP vapor tube and crankcase ventilation tube and intake manifold vacuum hose. Release the wire harness retainer from the crash bracket first as a part of the necessary steps. You should tighten the crash bracket bolts to 25 Nm (18 lb-ft) after installation. Disconnect the eight fuel injector electrical connectors as well as the fuel rail pressure and temperature sensor vacuum hose combined with its electrical connector and the EGR module vacuum and electrical connectors. Begin by removing intake manifold shield bolts while torquing them to 10 Nm (89 lb-in) and then switch to the four fuel rail bolts which require the same torque value of 10 Nm (89 lb-in). Separate the fuel rail and fuel injectors from each other yet discard the O-ring seals because these special fuel-resistant components should not return to service. The vehicle requires a repower of its fire suppression system after fire suppression system installation. Follow the removal steps in reverse direction while installing new upper and lower fuel injector O-ring seals that require engine oil lubrication before installation.

The presence of flammable mixtures during fuel rail servicing requires workers to keep away from both smoking and open flame devices near fuel-related parts. The system requires pressure relief before any fuel component disconnection to stop unwanted spray of fuel. The first step requires fixing the vehicle on a hoist into the NEUTRAL position while uninstalling the battery ground cable. First detach the spring lock coupling on the fuel rail before taking out the throttle body (TB) and exhaust gas recirculation (EGR) system module to exhaust manifold tube. All components such as the brake booster vacuum hose and evaporative emission (EVAP) canister purge valve hose and positive crankcase ventilation (PCV) tube and intake manifold vacuum hose should be detached from the throttle body spacer before setting them aside for further work. Begin by detaching the crash bracket wire harness retainer and remove any crash bracket bolts which might apply. The left-hand front fuel rail stud bolt receiver should be unclipped while all eight fuel injector electrical connectors get detached together with the right-hand rear fuel rail stud bolt ground connection. The disconnect procedure includes separating the fuel rail pressure and temperature sensor vacuum connections from the electrical connectors while also removing the vacuum and electrical attachments of the EGR system module. Start the removal sequence by removing first the shield bolts and shield and afterward the fuel rail stud bolts which total four in number. The technicians uninstall the fuel rail assembly together with its fuel injectors. The installation procedure demands new fuel-resistant O-ring seals which should replace all previous O-rings due to leak prevention needs. Reposition your fuel injectors from the fuel rail and apply engine oil to the O-ring seal components before following the opposite order for installation. Use tight torque values of 25 Nm (18 lb-ft) for crash bracket bolts and 12 Nm (9 lb-ft) for intake manifold shield bolts as well as 10 Nm (89 lb-in) for fuel rail stud bolts.

Service the fuel rail with safety measures in place which prohibits smoking or open flames near the fuel components because flammable mixtures remain present. First put the vehicle into neutral mode then use the hoist equipment. If you need to work with the fuel system you should reduce system pressure and disconnect the ground cable from the battery. Begin by disconnecting the locked fuel tube spring coupling of the fuel rail followed by the removal of the throttle body coupled with the EGR system module to exhaust manifold tube. The brake booster vacuum hose alongside the evaporative emission (EVAP) canister purge valve hose and PCV tube and EGR system module vacuum supply hose should be disconnected from the TB spacer area then carefully placed away. After removing the wire harness retainer from the crash bracket, personnel must uninstall both the crash bracket bolts and bracket before reinstallation. The bolts should be torqued to 25 Nm (18 lb-ft) at this step. Dismiss the wire harness retainer from the left-hand front fuel rail stud bolt then detach all eight fuel injector electrical connectors alongside the right-hand rear fuel rail stud bolt ground connector. Remove the vacuum and electrical connections of both the fuel rail pressure and temperature sensor and the EGR system module while disconnecting all electrical connectors. Replace the shield and bolt down its two intake manifold bolts using a torque of 10 Nm (89 lb-in). After removing the four fuel rail stud bolts the installer should tighten them to 10 Nm (89 lb-in) before reinstalling them. A special fuel-resistant material should be used to make O-ring seals due to leak risks from using ordinary O-ring seals. Carefully extract the combined fuel rail and fuel injector assembly. Proceed to discard original O-ring seals and apply clean engine oil to fuel injector O-ring suns before reinstallation following the reversal of removal steps.

If applicable, detach the crash bracket wire harness retainer and remove the crash bracket bolts.

Detach the fuel tube spring lock coupling, remove the throttle body, and take out the EGR system module tube.

Install the fuel rail and injectors as an assembly, securing the fuel rail studs to 10 Nm (89 lb-in).

Avoid smoking or open flames near fuel components, relieve fuel system pressure before disconnecting any fuel tubes, and disconnect the battery ground cable when working on the EVAP system or fuel-related components.

Disconnect the ground connector from the RH rear stud and the generator harness retainer from the LH front stud, then disconnect the eight fuel injector electrical connectors.