Ford Fusion: Fuel Charging and Controls - 1.5L EcoBoost (118kW/160PS) – I4 / Fuel Rail. Removal and Installation

Special Tool(s) / General Equipment

	303-1567 Sizer, Teflon Seal TKIT-2010C-FLM
	307-005 (T59L-100-B) Slide Hammer
	310-205 Fuel Injector Brush
	310-206 Remover, Fuel Injector TKIT-2009A-FLM
	310-206-01 Adapter for 310-206
	310-207 Installer, Fuel Injector Seal Assembly TKIT-2009A-FLM

Removal

1. Release the fuel system pressure.
   Refer to: Fuel System Pressure Release (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
   

1. Disconnect the battery.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. Remove the Ignition Coil-On-Plugs.
   Refer to: Ignition Coil-On-Plug (303-07A Engine Ignition - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
   

1. Detach the wiring harness retainers and disconnect the FRP sensor electrical connector.
   

1. NOTICE: 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.

   Disconnect the high-pressure fuel tube flare nuts. Remove and discard the high-pressure fuel tube.
   

1. NOTICE: Pull out the fuel rail in the direction of the fuel injector axis or damage may occur to the fuel injectors.

   NOTE: Use compressed air to remove any dirt or foreign material from the cylinder head, the 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 fuel injector by hand to break it loose may allow the fuel injector to be removed by hand.

   NOTE: Should any of the fuel injectors remain in the head, then the fuel injector electrical connectors will need to be disconnected as the fuel rail is being removed.

   Disconnect the fuel injector main wire harness electrical connector, remove the fuel rail bolts, then remove the fuel rail.
   

1. Disconnect the fuel injector electrical connectors, then remove the fuel injectors from the fuel rail.
   

1. NOTICE: 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.

   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.

1. Remove and discard the fuel injector clips.
   

1. NOTICE: Do not use compressed air to clean the tip of the fuel injector.

   NOTICE: 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, block and the general surrounding area of the fuel rails and injectors.

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

Installation

1. NOTE: Note the correct orientation of the fuel injector support rings for 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.
     

1. NOTICE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.

   NOTICE: 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 with narrow tip pliers.
      
   2. Carefully cut, remove and discard the lower fuel injector Teflon® seals.
      

1. NOTICE: Do not lubricate the new lower Teflon® fuel injector seals.

   1. Install the Arbor (part of the Fuel Injector Seal Installer) on the fuel injector tips.
      Use Special Service Tool: 310-207  Installer, Fuel Injector Seal Assembly.

   2. NOTICE: Once the Teflon® seal is installed on the Teflon® Seal Guide, it should immediately be installed onto the fuel injector to avoid excessive expansion of the Teflon® seal.

      NOTE: Make sure that new lower fuel injector Teflon® seals are installed.

      Install the new Teflon® seals onto the Arbor, using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon® seals along the Arbor.
      
   3. Using the Pusher Tool, slide the Teflon® seals off of the Teflon® Seal Guide and into the groove on the fuel injectors.
      Use Special Service Tool: 310-207  Installer, Fuel Injector Seal Assembly.
   4. Remove the special tools.
      

1. NOTICE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion.

   NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.

   1. Massage and warm the Teflon® seal with your fingers before the Teflon® seal sizer tool is installed. This will aid in installing the Teflon® seal sizer tool.
      
   2. Position the Teflon® seal sizer tool with the larger opening towards the Teflon® seal. Push while turning the Teflon® seal sizer tool 180 degrees.
      Use Special Service Tool: 303-1567  Sizer, Teflon Seal.
   3. Once the Teflon® seal sizer tool is installed, check and make sure the Teflon® seal is in the sizing portion of the Teflon® seal sizer tool.
      
   4. After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.
      

1. NOTICE: Use new fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.

   NOTICE: Do not lubricate the new lower Teflon® fuel injector seals.

   
   
   • Install the new the fuel injector support rings as noted during removal.
     
   • Install the new fuel injector O-rings and lubricate with clean engine oil.
     

1. Install the new the fuel injector clips.
   

1. NOTICE: The FRP sensor must be replaced only if it is removed from the fuel rail.

   NOTE: The fuel injector clip must lock into the slot of the fuel rail cup.

   Install the fuel injectors to the fuel rail, then connect the fuel injector electrical connectors.
   Refer to: Fuel Rail Pressure (FRP) Sensor (303-14A Electronic Engine Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
   

1. NOTICE: Do not lubricate the new lower Teflon® fuel injector seals.

   NOTE: Only tighten the fuel rail bolts finger tight at this stage.

   • Install the fuel rail, push down on the fuel rail above the injectors. Install and tighten the fuel rail bolts in the sequence shown.
     Torque: 17 lb.ft (23 Nm)
   • Connect the fuel injector main wire harness electrical connector.
     

1. NOTICE: Make sure that a new high pressure fuel tube is installed.

   NOTE: Only tighten the high pressure fuel tube flare nuts finger tight at this stage.

   NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas.

   Tighten the high-pressure fuel tube flare nuts in the following 3 stages.
   Torque:
     Stage 1:  15 lb.ft (21 Nm)
     Stage 2:  Wait 5 min
     Stage 3:  15 lb.ft (21 Nm)

1. Attach the wire harness retainers and connect the FRP electrical connector.
   

1. Install the ignition coil-on-plugs.
   Refer to: Ignition Coil-On-Plug (303-07A Engine Ignition - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
   

1. Connect the battery.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. Pressurize the fuel system.
   Refer to: Fuel System Pressure Release (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).