This procedure covers the removal and replacement of a single fuel injector on the 3.5L EcoBoost V6 engine, including fuel system depressurization and fuel rail removal.

Warnings

Tools required

Parts

• Fuel injector × 1 — Use OEM Ford fuel injector for 3.5L EcoBoost
• Fuel injector O-ring kit × 1 — Upper and lower O-rings
• Fuel line O-rings × 1 — Fuel rail supply line O-rings

Preparation

1. Ensure engine is completely cold
2. Park vehicle on level surface and engage parking brake
3. Disconnect negative battery terminal and wait 2 minutes for system de-energization
4. Place drain pan and shop towels under work area to catch fuel spillage
5. Remove engine cover by pulling upward on cover to release retention clips

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pressure test port on the fuel rail (passenger side). Attach fuel pressure gauge to the Schrader valve. Open the gauge valve to bleed fuel pressure into an approved container until pressure reads zero. Remove gauge and cap the test port.
2. 2

   Disconnect fuel supply line
   Locate the fuel supply line at the fuel rail on the driver side. Using the appropriate fuel line disconnect tool, press the tool into the quick-connect fitting and pull the line away from the fuel rail. Have shop towels ready as residual fuel will drain. Inspect the O-rings on the line and replace if damaged.
3. 3

   Disconnect electrical connectors
   Disconnect the electrical connector from the fuel injector being replaced by pressing the release tab and pulling straight up. Also disconnect all other fuel injector connectors to allow fuel rail removal. Note the routing of the injector harness for reinstallation.
4. 4

   Remove fuel rail mounting bolts
   Using an 8mm socket, remove the four fuel rail mounting bolts (two per side). These bolts secure the fuel rail to the intake manifold. Keep bolts organized for reinstallation.
   Torque spec

   Fuel Rail Bolts12 Nm (9 lb-ft)
5. 5

   Remove fuel rail assembly
   Carefully lift the fuel rail assembly upward with even pressure on both sides. The injectors will pull out of the intake manifold. Work slowly to avoid damaging injector tips or O-rings. Once free, place the fuel rail on a clean work surface with injectors facing upward.
6. 6

   Remove defective fuel injector
   Identify the injector to be replaced. Using needle nose pliers, remove the metal retaining clip securing the injector to the fuel rail. Pull the injector straight out of the fuel rail. If the injector is stuck, use an injector puller tool to avoid damaging the fuel rail. Note the orientation of the injector for proper installation.
7. 7

   Prepare new fuel injector
   Remove the new injector from packaging. Lubricate the new upper and lower O-rings with clean engine oil. Install the upper O-ring onto the injector body in the groove closest to the electrical connector. Install the lower O-ring in the groove at the tip of the injector. Ensure O-rings are seated properly in their grooves.
8. 8

   Install new fuel injector
   Align the new injector with the fuel rail bore, matching the orientation of the other injectors. Push the injector straight into the fuel rail until it seats completely. Install the metal retaining clip to secure the injector, ensuring the clip snaps into place on both sides.
9. 9

   Clean injector ports
   Before reinstalling the fuel rail, inspect the injector ports in the intake manifold. Remove any debris or old O-ring material using a clean shop towel. Do not allow any foreign material to fall into the intake manifold ports.
10. 10

    Reinstall fuel rail assembly
    Carefully align all six injectors with their respective ports in the intake manifold. Apply even downward pressure on both sides of the fuel rail to seat all injectors simultaneously. Ensure the fuel rail mounting bosses align with the bolt holes. Install the four fuel rail mounting bolts finger-tight, then torque in a criss-cross pattern to specification.
    Torque spec

    Fuel Rail Bolts12 Nm (9 lb-ft)
11. 11

    Reconnect electrical connectors
    Reconnect the electrical connector to each fuel injector, ensuring each connector clicks into place. Verify proper connection by gently pulling on each connector. Route the injector harness as noted during disassembly.
12. 12

    Reconnect fuel supply line
    Install new O-rings onto the fuel supply line if removed. Push the fuel supply line straight into the fuel rail quick-connect fitting until it clicks. Tug on the line to verify it is locked in place.
13. 13

    Reconnect battery and prime fuel system
    Reconnect the negative battery terminal. Turn the ignition key to the ON position (do not start) for 5 seconds, then OFF. Repeat this cycle three times to prime the fuel system and pressurize the fuel rail. Check all connections for fuel leaks.

Reassembly

1. Reinstall engine cover by aligning clips and pressing down until seated
2. Wipe up any spilled fuel and dispose of contaminated shop towels properly
3. Double-check all electrical connections and fuel line security before starting engine

Verification

• Start the engine and let it idle for 2 minutes while inspecting for fuel leaks at the fuel rail, injector connections, and supply line
• Check for proper engine operation with no rough idle, misfires, or fuel odor
• Verify no diagnostic trouble codes are present using a scan tool
• Test drive the vehicle to confirm normal acceleration and performance

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