Ford 5C3Z-9F792-DA
Fuel Rail

Service the fuel rail by first implementing safety protocols to block open flames and smoking everywhere in the area because the rail contains potentially dangerous flammable mixtures. A safety precaution should include releasing fuel system pressure to stop fuel spraying since the system sustains high pressure levels when the engine shuts off. It is essential to work with clean conditions during fuel injection component handling and to seal open orifices with blanking plugs. The service begins with grounding the battery cable before removing the Air Cleaner outlet pipe then disconnecting the fuel supply tube spring lock coupling. The technician should disconnect the Electronic Throttle Control electrical connector as well as the Throttle Position sensor electrical connector together with the fuel rail pressure and temperature sensor electrical and vacuum connectors and finally the ten fuel injector electrical connectors. Access the fuel rail better for removal by detaching engine wiring harness retainers from the intake manifold so only the fuel injectors stay inside the manifold. The removal of six bolts enables separating the fuel rail from the injectors so you can remove the fuel rail. Use new special fuel-resistant material O-rings for installation after applying clean engine oil on them and tighten bolts to 10 Nm (89 lb-in). Extract the fuel injectors from engine intake manifold while throwing away their upper and lower O-ring seals. Service and replacement of the fuel rail pressure and temperature sensor require both bolt removal along with discarding the O-ring seal before performing the reverse installation steps.

It is necessary to stay away from smoking and utilize any open flames near fuel components because highly flammable mixtures present a risk of personal injury during fuel rail servicing operations. Before removing any fuel lines or components from the high-pressure fuel system it becomes necessary to first reduce fuel system pressure. Start the process by breaking free the spring lock coupling from the fuel rail before taking out the upper intake manifold. After disconnecting all electrical connections from the fuel rail pressure sensor the vacuum system one should proceed to remove the six fuel injector electrical connectors. Pull off the wire tie then release the wiring harness retainers from the front of the fuel rail. Proceed by loosening four bolts fastening the fuel rail and injectors and then tighten them to 10 Nm (89 lb-in) when reinstalling the assembly. Using clean engine oil to lubricate the O-ring seals and discarding the old ones is necessary before performing the installation procedure in reverse order.

Prior to servicing the fuel rail system it is essential to follow safety protocols regarding its highly flammable content since this prevents personal injury. Start the procedure by disconnecting the battery ground cable followed by air cleaner removal and intake pipe extraction. Remove the quick connect fitting of evaporative emission canister purge valve and the heated positive crankcase ventilation valve electrical connector together with PCV hose from intake manifold. The next step of the repair involves disconnecting four pieces: the electronic throttle control connector with the throttle position sensor electrical connector and the vacuum hose at the rear of the valve cover and the pressure temperature sensor electrical connector alongside the FRPT sensor vacuum hose. Detach all eight fuel injector electrical connectors and spring lock couplings from the fuel rail before removing its four bolts which need to be tightened to 89 lb-in (10 Nm) during reinstallation. Every fuel injector should be tightly secured in its injector cup before adding clean engine oil to the new O-ring seals. The complete removal of fuel rail and injectors should be done together as one unit whereas new fuel rail installations require removal of the two FRPT bolts and FRPT sensor followed by torquing them to 4 Nm (35 lb-in). Some check the O-ring seal condition before deciding if replacement is needed. After that the reverse procedure allows the work to finish.

Remove the air cleaner and intake pipe.

Remove the upper intake manifold.

Disconnect the spring lock coupling at the fuel rail.

Remove the two bolts, discard the O-ring seal, install the new sensor, and tighten to 4 Nm (35 lb-in).

Install the fuel injectors along with the hold-down clamps and bolts, tightening them to 2 Nm (18 lb-in).

Remove the two bolts securing the fuel rail pressure and temperature sensor and tighten them to 4 Nm (35 lb-in) upon installation.