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Removal and Installation

WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.
    WARNING: If equipped with fire suppression system, depower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM .
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  4. Disconnect the fuel tube spring lock coupling from the fuel rail. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  5. Remove the throttle body (TB). For additional information, refer to THROTTLE BODY .
  6. Remove the exhaust gas recirculation (EGR) system module to exhaust manifold tube. For additional information, refer to ENGINE EMISSION CONTROL .
  7. Disconnect the brake booster vacuum hose from the TB spacer and position aside.
  8. Disconnect the evaporative emission (EVAP) canister purge valve hose quick connect coupling from the TB spacer and position aside. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  9. Disconnect the positive crankcase ventilation (PCV) tube quick connect coupling from the TB spacer and position aside. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  10. Disconnect the intake manifold vacuum hose from the TB spacer and position aside.
  11. If equipped, detach the crash bracket wire harness retainer.
  12. Remove the 2 crash bracket bolts, and the bracket.
    • To install, tighten to 25 Nm (18 lb-ft).
  13. Remove the wire harness retainer from the LH front fuel rail stud bolt and position aside.
  14. Disconnect the 8 fuel injector electrical connectors.
  15. Disconnect the ground connector from the RH rear fuel rail stud bolt and position aside.
  16. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
  17. Disconnect the exhaust gas recirculation (EGR) system module vacuum and electrical connectors.
  18. Remove the 2 intake manifold shield bolts and the shield.
    • To install, tighten to 12 Nm (9 lb-ft).
  19. Remove the 4 fuel rail stud bolts.
    • To install, tighten to 10 Nm (89 lb-in).
  20. Remove the fuel rail and the fuel injectors as an assembly.
    21. CAUTION: Use O-rings seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals.
  21. Separate the fuel injectors from the fuel rail.
    • Discard the O-ring seals.
    22. WARNING: Repower the fire suppression system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM .
  22. To install, reverse the removal procedure. If equipped with fire suppression system, repower the system.
    • Lubricate the fuel injectors O-ring seals with clean engine oil prior to installation.
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