How do I disconnect the electrical harness from the fuel rail of 2002 ml320

To remove a fuel injector or injectors you must remove the fuel supply rail that sits over them. Here is how you do that for both engine options, Turbo and non Turbo..

Removal & Installation

Except Turbocharged Models

WARNING Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or *****.

1. Release fuel system pressure.
2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose.
3. Remove the negative battery cable.
4. Remove the engine cover or throttle control shield if equipped.
   NOTE Wrap shop towels around hose to catch any gasoline spillage.
5. Disconnect fuel supply tube from rail.
6. Remove the Intake Manifold, refer to the Engine section.
7. Disconnect electrical connectors from fuel injectors.
8. Remove bolts holding fuel rail.
9. Remove the fuel rail and injectors.
10. Remove the injectors from the fuel rail.

To install:

1. Install injectors to the fuel rail.
2. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
3. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail bolts to 170-230 inch lbs. (19.5-25.5 Nm).
4. Attach electrical connectors to fuel injectors.
5. Connect fuel supply tube to fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery section
6. Install Intake Manifold, refer to the Engine section.
7. Install the engine cover or throttle control shield if equipped.
8. Install the negative battery cable.
9. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. Tighten air inlet tube clamps to 20-30 inch lbs. (2-4 Nm).

Turbocharged Models

WARNING Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or *****.

1. Release the fuel system pressure.
2. Disconnect the negative battery cable.
3. Disconnect the throttle body inlet hose and remove from throttle body.
4. Disconnect the purge hose from the throttle body.
5. Unlock and disconnect the electrical connection at the throttle body.
6. Remove the throttle control shield .
7. Remove the throttle and speed control cables from the throttle body.
8. Remove the cables from the throttle body bracket.
9. Unlock and disconnect the MAP sensor electrical connector.
10. Remove the vacuum lines from the rear of the intake manifold.
11. Remove the 5 bolts from the front of the intake manifold.
12. Remove the 2 bolts from the rear of the intake manifold.
13. Remove the intake manifold. Cover the lower intake manifold openings.
14. Drain the Coolant system.
15. Move the upper radiator hose clamp, so that the hose can be rotated up and out of the way.
16. Remove the 2 small hoses from the thermostat housing.
17. Remove the 2 bolts from the thermostat housing and rotate the assembly up and out of the way.
    NOTE Wrap shop towels around hose to catch any gasoline spillage.
18. Disconnect the fuel line from the fuel rail.
19. Unlock and disconnect the electrical connectors from the fuel injectors.
20. Remove the wiring harness from the fuel rail.
21. Remove the 2 bolts from the fuel rail.
22. Remove the fuel rail and injectors from the intake manifold.

To install:

1. Install the fuel injectors to the fuel rail.
2. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
3. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place.
4. Install the 2 bolts to the fuel rail. Tighten fuel rail bolts to 170-230 inch lbs. (19.5-25.5 Nm).
5. Install the wiring harness to the fuel rail.
6. Connect and lock the electrical connectors to the fuel injectors.
7. Connect the fuel line to the fuel rail.
8. Rotate the assembly back into place and install the 2 bolts to the thermostat housing tighten to 110 inch lbs. (12.5 Nm).
9. Move the upper radiator house clamp back into place.
10. Install the 2 small hoses to the thermostat housing.
11. Fill the Coolant system.
12. Install the intake manifold.
13. Install the 2 bolts to the rear of the intake manifold tighten to 250 inch lbs. (28 Nm).
14. Install the 5 bolts to the front of the intake manifold and tighten to 250 inch lbs. (28 Nm).
15. Install the vacuum lines to the rear of the intake manifold.
16. Connect and lock the MAP sensor electrical connector.
17. Install the cables to the throttle body bracket.
18. Install the throttle and speed control cables to the throttle body.
19. Install the throttle control shield.
20. Connect and lock the electrical connections at the throttle body.
21. Connect the purge hose to the throttle body.
22. Connect the throttle body inlet hose to the throttle body and tighten clamps to 20-30 inch lbs. (2-4 Nm).
23. Connect the negative battery cable.
24. Use the DRB® scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.

Removal & Installation

Except Turbocharged Models

WARNING Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or *****.

1. Release fuel system pressure.
2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose.
3. Remove the negative battery cable.
4. Remove the engine cover or throttle control shield if equipped.
   NOTE Wrap shop towels around hose to catch any gasoline spillage.
5. Disconnect fuel supply tube from rail.
6. Remove the Intake Manifold, refer to the Engine section.
7. Disconnect electrical connectors from fuel injectors.
8. Remove bolts holding fuel rail.
9. Remove the fuel rail and injectors.
10. Remove the injectors from the fuel rail.

To install:

1. Install injectors to the fuel rail.
2. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
3. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail bolts to 170-230 inch lbs. (19.5-25.5 Nm).
4. Attach electrical connectors to fuel injectors.
5. Connect fuel supply tube to fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery section
6. Install Intake Manifold, refer to the Engine section.
7. Install the engine cover or throttle control shield if equipped.
8. Install the negative battery cable.
9. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. Tighten air inlet tube clamps to 20-30 inch lbs. (2-4 Nm).

Turbocharged Models

WARNING Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or *****.

1. Release the fuel system pressure.
2. Disconnect the negative battery cable.
3. Disconnect the throttle body inlet hose and remove from throttle body.
4. Disconnect the purge hose from the throttle body.
5. Unlock and disconnect the electrical connection at the throttle body.
6. Remove the throttle control shield .
7. Remove the throttle and speed control cables from the throttle body.
8. Remove the cables from the throttle body bracket.
9. Unlock and disconnect the MAP sensor electrical connector.
10. Remove the vacuum lines from the rear of the intake manifold.
11. Remove the 5 bolts from the front of the intake manifold.
12. Remove the 2 bolts from the rear of the intake manifold.
13. Remove the intake manifold. Cover the lower intake manifold openings.
14. Drain the Coolant system.
15. Move the upper radiator hose clamp, so that the hose can be rotated up and out of the way.
16. Remove the 2 small hoses from the thermostat housing.
17. Remove the 2 bolts from the thermostat housing and rotate the assembly up and out of the way.
    NOTE Wrap shop towels around hose to catch any gasoline spillage.
18. Disconnect the fuel line from the fuel rail.
19. Unlock and disconnect the electrical connectors from the fuel injectors.
20. Remove the wiring harness from the fuel rail.
21. Remove the 2 bolts from the fuel rail.
22. Remove the fuel rail and injectors from the intake manifold.

To install:

1. Install the fuel injectors to the fuel rail.
2. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
3. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place.
4. Install the 2 bolts to the fuel rail. Tighten fuel rail bolts to 170-230 inch lbs. (19.5-25.5 Nm).
5. Install the wiring harness to the fuel rail.
6. Connect and lock the electrical connectors to the fuel injectors.
7. Connect the fuel line to the fuel rail.
8. Rotate the assembly back into place and install the 2 bolts to the thermostat housing tighten to 110 inch lbs. (12.5 Nm).
9. Move the upper radiator house clamp back into place.
10. Install the 2 small hoses to the thermostat housing.
11. Fill the Coolant system.
12. Install the intake manifold.
13. Install the 2 bolts to the rear of the intake manifold tighten to 250 inch lbs. (28 Nm).
14. Install the 5 bolts to the front of the intake manifold and tighten to 250 inch lbs. (28 Nm).
15. Install the vacuum lines to the rear of the intake manifold.
16. Connect and lock the MAP sensor electrical connector.
17. Install the cables to the throttle body bracket.
18. Install the throttle and speed control cables to the throttle body.
19. Install the throttle control shield.
20. Connect and lock the electrical connections at the throttle body.
21. Connect the purge hose to the throttle body.
22. Connect the throttle body inlet hose to the throttle body and tighten clamps to 20-30 inch lbs. (2-4 Nm).
23. Connect the negative battery cable.
24. Use the DRB® scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.

Possible causes
- Low or no fuel
- Faulty Fuel Rail Pressure Sensor
- Fuel Rail Pressure Sensor harness is open or shorted
- Fuel Rail Pressure Sensor circuit poor electrical connection
- Faulty Fuel Pump

First remove air cleaner top and hose then the upper intake plenum to incluke 8 bolts in middle the wire harness in rear and 2bolts 10 mm support bolts one on rear one by throttle body after that remove fuel line quick disconnect remove bolt under line then4 bolts hold down the lower intake fuel injectors drivers side injector harness now remove lower intake.

That is P0191 not o.
P0191 FORD - Fuel Rail Pressure Sensor Circuit Range/Performance

Possible causes- High fuel pressure
- Low fuel pressure
- Damaged FRP sensor
- Excessive resistance in the circuit
- Low or no fuel
- Wiring harness connector of the fuel pressure sensor
- Fuel Rail Pressure Sensor
-

so that mean the old one is all ready removed.?
or did you mean all steps in the fsm for INJECTOR.
the steps are the same on all EFI fuel rail injectors.
you could google that or you tube it or read the FSM.

hide call keys from step 2 on, or very bad things can happen.
(wife or kids no aware of danger)
ill just cover the (basics)
1: per FSM , depressurize the system, in can be at 60PSI
parked. so avoid fuel in eyes, or a fire. we do that first.
gain access to rail under failure. (RUF) (no barking)
2: remove injector X , wire plug. (failing)
3: then detach the injector rail clamps the both rails off as one....
injector are all now loose, to pull off.
4: add new seals to new injector, and install in reverse order.

that's it, only the gain access , varies,... mostly.

last depressure steps:
run engine,
remove fuel pump relay, engine stalls. key off, hide keys!

next tje FSM words (just the OFF section)

1. Remove fuel tank filler tube cap.
2. Perform Fuel System Pressure Release Procedure.
3. Remove negative battery cable at battery.
4. Remove air duct at throttle body air box.
5. Remove air box at throttle body.
6. Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection.
7. Remove necessary vacuum lines at throttle body.
8. Disconnect electrical connectors at all 6 fuel injectors. Push red colored slider away from injector. While pushing slider, depress tab and remove connector from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.
9. Disconnect electrical connectors at throttle body sensors.
10. Remove 6 ignition coils.
11. Remove 4 fuel rail mounting bolts.
12. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in cylinder head. Gently rock and pull right side of rail until injectors just start to clear cylinder head holes. Repeat this procedure (left/right) until all injectors have cleared cylinder head holes.
13. Remove fuel rail (with injectors attached) from engine.

end expert.

alldata.com
login and read all steps. that be best , then ask questions?

To replace the fuel injectors,first the fuel pressure needs to be relieved, then remove engine appearance cover.Then remove air cleaner and air cleaner ducting.Then comes vacuum hoses,remove the hoses and electrical connectors that prevent you from accessing the fuel rail. Disconnect the fuel send and return lines and unplug the electrical connectors for the fuel injectors. -------- You will need socket wrench to relieve fuel pressure and to remove bolts on fuel rail. Complete fuel rail assembly will come out with injectors,then you will have to remove injectors from fuel rail. -------- With new fuel injectors use new O-ring.Don't use old O-ring,use new O-ring. ---------- This will help.Thanks.Helpmech.

Fig. 1: Supercharger assembly and related parts

REMOVAL & INSTALLATION

1. Disconnect the negative battery cable.
2. Remove the accessory drive belt from the supercharger pulley.
3. Relieve the fuel pressure and remove the fuel injector sight shield.
4. Disconnect the fuel pipes from the fuel rail and vacuum hose at the pressure regulator.
5. Disconnect the electrical connectors from the fuel injectors and remove the fuel rail mounting bolts. Remove the fuel rail with the injectors intact.
6. Disconnect the electrical connectors at the IAC, TPS, MAF, EGR and boost control solenoid. Lay the wiring harness aside.
7. Remove the air intake duct and remove the EGR pipe from the supercharger.
8. Disconnect the throttle cable and the cruise control cable. Remove the cable bracket.
9. Remove the tensioner bracket to supercharger mounting stud.
10. Remove the supercharger to intake manifold bolts, remove the supercharger from the intake manifold. Remove the supercharger gasket and coolant passage O-rings. To install:
    
11. Replace the oil passage O-rings and the supercharger gasket.
12. Install the supercharger and bolts. Install the tensioner bracket-to-supercharger bolt. Tighten the bolts to 19 ft. lbs. (26 Nm).
13. Install the cable bracket and connect the throttle and cruise control cables.
14. Connect the EGR pipe to the supercharger and install the air intake duct.
15. Connect the electrical connectors to the IAC, TPS, MAF, EGR and boost control solenoid.
16. Install the fuel rail and bolts and tighten the bolts to 15 ft. lbs. (24 Nm).
17. Connect the connectors to the fuel injectors and the vacuum hoses at the pressure regulator.
18. Connect the fuel pipes to the fuel rail and install the fuel injector sight shield.
19. Install the accessory drive belt to the supercharger and connect the negative battery cable.

Please don't forget to rate!

1. Remove the air cleaner assembly if necessary for access to the sensor.
   
2. Disconnect the pigtail harness from the sensor.
   
3. Remove the nut holding the sensor wire clip to the fuel rail mounting stud.
   
4. Remove the sensor mounting hardware, then the sensor.
   
5. Remove the clip from the sensor wire harness.
   

To install:

1. Install the sensor flush against the opening.
   
2. Install and tighten the bolts or nuts, as applicable.
   
3. Install the electrical connector.
   
4. Install the clip on the sensor wire harness.
   
5. Install the clip over the fuel rail mounting stud. Install the clip mounting nut.
   

These 4 pictures are for the Automatic:








These are for a manual trans:

here is the answer,follow these steps one by one please: (1)relieve fuel pressure by using a fuel pressure gauge that also has a bleeder valve on it (2)disconnect the negative battery terminal (3)remove the intake manifold service cover (4)remove air intact duct between the air cleaner housing and the throttle body gasket.also remove the throttle body spacer bolts,remove the spacer and remove thegasket.discard the old gaskets. (5)Disconnect the fuel supply and return lines from the fuel rail. 960Disconnect the vacuum hose from the fuel pressure regulator. (6)Remove the nut that attaches the fuel rail end-point bracket retainer. (7)Disconnect the electrical connectors form all 8 fuel injectors and set the fuel injector harness aside. (8)Remove the fuel rail mounting bolts. (9)Remove the fuel rail and the fuel injectors as a single assembly. (10)Remove the fuel injectors one by one,by flipping up the U-clip retainer then pulling the injector from the fuel rail. (11)Remove the old O-rings from the injectors and be sure to use new ones when installing the new injectors. (12)Also use a new gasket when installing the spacer,also use a new throttle body gasket.>>when finished start car and check for leaks.and you're done.