Fuel Rail Assembly

Tools Required:

• Spring Lock Coupling Disconnect Tool D87L-9280-A (3/8 inch) or D87L-9280-B (1/2 inch)

Removal

1. Perform Steps 1 through 4 under Fuel Charging Assembly, Pre-Service Procedures.

2. Remove upper manifold assembly as outlined.

3. Remove spring lock coupling retainer clip from fuel inlet and return fittings.

4. Using Spring Lock Coupling Disconnect Tool D87L-9280-A or B or equivalent, disconnect the crossover fuel hose from the fuel rail assembly as outlined.

   NOTE: The following items should be noted when service is required:

   • Use specified tool or equivalent.
   • Inspect for missing or damaged O-rings.
   • Use the specified Service Replacement O-rings, Kit No. E4PZ-9229-A, F9PE-90509-AA (cold climate) or equivalent.
   • Lubricate the O-ring with clean engine oil.
   • Check to ensure that the fitting is locked.

5. Remove four fuel rail assembly retaining bolts (two on each side).

   NOTE: It may be easier to remove injectors with the fuel rail as an assembly.

6. Carefully disengage fuel rail from fuel injectors and remove fuel rail.

7. Use a rocking, side-to-side motion while lifting to remove injectors from fuel rail.
   
   Mustang Shown, Cobra Similar
   
   
   
   
   
   

   Item	Part Number	Description
   1	9C968	Fuel Pressure Regulator
   2	9F792	Fuel Rail Assy
   3	9K461	Lower Intake Manifold Assy
   4	9F593	Injector Assy (8 Req'd)
   5A	—	1/4-20 x .75 Bolt (4 Req'd)
   A		Tighten to 8-12 Nm (71-106 Lb-In)

Installation

NOTE: When installing fuel rail assemblies with new or used injectors particular attention should be paid to proper seating of O-rings to ensure that no fuel leaks exist.

1. Push fuel rail down to ensure all injector O-rings are fully seated in the fuel rail cups and intake manifold.

2. Install retaining bolts while holding fuel rail down. Tighten bolts to 8-12 Nm (71-106 lb-in).

3. Install spring-lock coupling as outlined.

4. With injector wiring disconnected, turn ignition to the RUN position to allow the fuel pump to pressurize the system.

5. Using a clean towel check for fuel leaks.

6. Connect fuel injector wiring harness.

7. Install upper intake manifold assembly as outlined.

8. Run engine at idle for two minutes.

9. Turn engine OFF and inspect for leaks.