Ford Ecosport: Fuel Charging and Controls - 2.0L Duratec-HE (129kW/175PS) / Removal and Installation - Fuel Rail

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
	310-207 Installer, Fuel Injector Seal Assembly TKIT-2009A-FLM

Removal

1. Release the fuel system pressure.
   Refer to: Fuel System Pressure Release (310-00C Fuel System - General Information - 2.0L Duratec-HE (129kW/175PS), General Procedures).
   

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

1. Remove the intake manifold.
   Refer to: Intake Manifold (303-01C Engine - 2.0L Duratec-HE (129kW/175PS), Removal and Installation).
   

1. Remove the accessory drive belt tensioner.
   Refer to: Accessory Drive Belt Tensioner (303-05C Accessory Drive - 2.0L Duratec-HE (129kW/175PS), Removal and Installation).
   

1. NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.

   Remove the fuel injection pump noise insulator.
   

1. NOTICE: To release the fuel pressure in the high pressure fuel tube, wrap the fuel injection pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of fuel injection pump flare nut.

   Remove the high pressure fuel tube bracket bolts. Loosen the high pressure fuel tube flare nuts, then remove and discard the high pressure fuel tube.
   

1. Remove the bolt, nuts and the crash bracket.
   

1. Detach the fuel charge wire harness retainers from the fuel rail, then remove the fuel rail insulator.
   

1. Disconnect the fuel injector electrical connectors, then disconnect the fuel rail pressure sensor electrical connector.
   

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

   NOTICE: The isolator on the bottom of the fuel injector may fall off during removal. Look for any loose pieces and remove them. If this occurs replace the fuel injector.

   NOTE: Use compressed air and 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.

   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 injector by hand to break it loose may allow the injector to be removed by hand.

   Remove the fuel rail bolts and then remove the fuel rail.
   

1. Remove the fuel injectors from the fuel rail.
   

1. Remove and discard the fuel injector clips.
   

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.

   Using the special tools, remove any of the fuel injectors that remained in the cylinder head.
   Use Special Service Tool: 307-005 (T59L-100-B)  Slide Hammer. , 310-206  Remover, Fuel Injector.

1. NOTICE: 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.

   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.

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

1. 1. Remove and discard the fuel injector O-ring seals.
      

   2. NOTE: Note the correct orientation of the fuel injector support rings, to aid in the correct installation of the new fuel injector support rings.

      Remove and discard the fuel injector support rings.
      
   3. Inspect the inlet stopper, if it is damaged or comes off then discard the inlet stopper. The inlet stopper is not needed for proper function. Ensure that any debris from the inlet stopper are removed. If the inlet stopper is intact and undamaged do not remove the inlet stopper from the fuel injector.
      

Installation

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

   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.
      
   2. Carefully cut and discard the lower fuel injector Teflon® seal.
      

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

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

1. 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. NOTE: Make sure that new fuel injector support rings and new fuel injector O-ring seals are installed.

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

      Install the new fuel injector O-ring seals and lubricate with clean engine oil.
      Refer to: Specifications (303-01C Engine - 2.0L Duratec-HE (129kW/175PS), Specifications).
      

   2. NOTICE: The new the fuel injector support rings must be installed in the correct orientation with the wide surface area facing up against the fuel injector O-ring seals. Improperly installed support rings may cause the fuel system to leak.

      Install the new the fuel injector support rings.
      
   3. Inspect the inlet stopper, if it is damaged or comes off then discard the inlet stopper. The inlet stopper is not needed for proper function. Ensure that any debris from the inlet stopper are removed. If the inlet stopper is intact and undamaged do not remove the inlet stopper from the fuel injector.
      
   4. The upper side of the support ring has the wide surface area.
      
   5. The fuel injector support ring.
      
   6. The lower side of the support ring has the narrow surface area.
      

1. NOTE: Make sure that new fuel injector clips are installed.

   Install the new the fuel injector clips.
   

1. NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.

   NOTE: The fuel rail pressure sensor must be replaced if it is removed from the fuel rail.

   Install the fuel injectors to the fuel rail.
   

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

   NOTE: No sudden impact force is allowed.

   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: 18 lb.ft (25 Nm)

1. Connect the fuel rail pressure sensor electrical connector, then connect the fuel injector electrical connectors.
   

1. Install the fuel rail insulator, then attach the fuel charge wire harness retainers to the fuel rail.
   

1. Install the crash bracket, then install and tighten the bolt and the nuts.
   Torque:
      Tighten the bolt to :   177 lb.in (20 Nm)
      Tighten the nuts to :   106 lb.in (12 Nm)

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

   
   Position a new high-pressure fuel tube and hand start the flare nuts. Loosely install the high pressure fuel tube bracket bolts.
   
   1. Tighten the high pressure fuel tube flare nuts in the following 2 stages.
      Torque:
        Stage 1:  Tighten the high pressure fuel tube flare nuts first to: :   89 lb.in (10 Nm)
        Stage 2:  Tighten an additional: :   30°
   2. Tighten the high-pressure fuel tube bracket bolts.
      Torque: 89 lb.in (10 Nm)

1. NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.

   Install the fuel injection pump noise insulator.
   

1. Install the accessory drive belt tensioner.
   Refer to: Accessory Drive Belt Tensioner (303-05C Accessory Drive - 2.0L Duratec-HE (129kW/175PS), Removal and Installation).
   

1. Install the intake manifold.
   Refer to: Intake Manifold (303-01C Engine - 2.0L Duratec-HE (129kW/175PS), Removal and Installation).
   

1. Reconnect 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 (310-00C Fuel System - General Information - 2.0L Duratec-HE (129kW/175PS), General Procedures).