Remove the pressure from the fuelling system and remove the connection of the negative terminal of the battery. For turbocharged models raise the engine cover off the ballstuds and set it aside also remove the ignition coils. On 1.6L engines, the air filter housing outlet duct, crankcase vent pipe quick-connect fitting from the turbocharger inlet pipe as well as the pipe should be removed. Replace the fuel pump insulator fasteners and lift the insulator in the following way: To the best of my understanding, for the 2.0L and 2.7L engines, the intake manifold must be removed. On all engines, in the 2.7 V6, liftoff the high pressure fuel pump cover, unbolt the high pressure fuel lines from the fuel pump and fuel rail and the vendor recommends that if the fuel lines are to be removed they should be replaced. On 1.5L and 2.0L models, remove the electrical connectors connected to any wiring that is bundled with the harness of the fuel injectors and the four connectors of fuel injectors. Clean the area around each injector with compressed air and then unbolt the fuel rail mounting fasteners after which they be discarded after which remove the fuel rail as well as the injectors and on replacement, new fuel rail bolts must only be used. Pull off each fuel injector retaining clip and dispose of the upper injector O-rings, this being done for all injectors. If any of the injectors stick in the cylinder head, you can use a special tool; the slide hammer will pull them. Take out the sealing Teflon ring for combustion chamber, upper O-ring and the support ring from each injector with a due precaution not to mar the groove for seal. Cleaning is however paramount before the installation of the new Teflon seal and the groove for the seal and the injector shaft. Special tools should be used in connection with the setting of Teflon lower seals to the injectors and no lubricants should be used. If specialized instruments are not handy the use of a socket can also be used to install the Teflon seal alongside a piece of plastic tubing to compress the seal back into its usually size. Screw a new support ring on the top of the injector, lubricate the new upper O-ring with clean engine lubricant and fit it into the injector. Remove the remaining plastic injector plugs, use a small nylon brush to clean the injector bores, then thread each injector into its bore in the fuel rail and clip the new press-fit retainer in place. Before or after that, position and fix the injectors together with the fuel rail assembly on the cylinder head, tightening the fuel rail mounting fasteners to the marked force. The rest of installation is vice-versa of removal. For non-turbocharged models, on 2.3L and 2.5L engines, remove the air intake duct for the alternator and detach the fuel supply line connector from the fuel rail; also, remove the fuel rail gasket. Remove battery connectors from all the wiring that uses the harness together with the fuel injectors, pull out both fuel rails with their injectors as a single unit. Pull off each fuel injector retaining clip and dispose of the upper and lower injector O-rings, on all injectors. Clean the new upper and lower O rings with fresh engine oil and fit them in to the injectors. Place the injectors and fuel rail assembly onto the intake manifold and run the fuel rail mounting fasteners to the appropriate tension. Everything that is said about the removal can be equally applied to the remainder of installation. Connect the cable to the negative terminal, start the switch to ON so that the fuel pump will turn ON and look for signs of fuel leakage. For 3.0L and 3.5L V6 engines, erase upper intake manifold and relieve fuel rail connection at fuel rail and unplug the varieties of engine harness retainers. Remove the electrical connector from each fuel injector, unlatch the fuel rail and injectors and remove the fuel injector retaining clip in order to remove each injector. The upper and lower injector O-rings should be unscrewed from the respective injector and then disposed. Clean the new upper and lower O-rings with clean engine oil and fit on the injectors. Refit the injectors to the fuel rail with the help of the retaining clips, fit new intake manifold gaskets where applicable on 3.0L engine and engage the fuel rail assembly on the intake manifolds with the help of the bolts which ought to be tightened by hand. Be careful when tightening the fuel rail bolts and the rest is done in the reverse manner to that of the removal process. Connect the cable to the negative terminal of the battery, start the vehicle by turning the key to 'ON' position in order to activate the fuel pump and look for spillage.
Posted by FordPartsGiant Specialist 
