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Home >> Ford >> 2003 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2539 (Fuel Charging System & Fuel Control System - 6.4L 99R Diesel -- F250-F550 Super Duty) >> Removal And Installation >> Fuel Rail >> Installation

Fuel Rail: Installation

WARNING: This page is about a different car, the 2010 Ford Pickup, 2010 Ford F550 Super Duty, 2010 Ford F450 Super Duty, and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Lubricate the fuel injector O-ring seal with clean engine oil.
  1. Install a new O-ring seal and a soft steel combustion gasket on the fuel injector.
    2. NOTE: Failure to tighten the fuel injector correctly may lead to engine failure.
    NOTE: To prevent engine damage, do not use air tools to install the fuel injector. The fuel injector hold-down clamp assembly bolt retainer that extracts the injector may dislodge and fall into the oil drain hole.
    NOTE: If the fuel injector hold-down clamp assembly bolt retainer is damaged or missing, a new fuel injector hold-down clamp assembly must be installed, or the clamp assembly will not be able to remove the fuel injector.
  2. Install the fuel injectors, the fuel injector hold-down clamps and the bolts.
    • Tighten to 2 Nm (18 lb-in).
  3. Install the fuel rail and the 2 bolts.
    • Tighten hand-tight.
    4. NOTE: Use a back-up wrench on the fuel injector fittings.
    NOTE: Use a crowfoot wrench to aid in tightening the fuel injector supply tube.
  4. Install the new fuel injector supply tubes in the following sequence.
    1. Remove the Fuel System Caps from the fuel rail and fuel injectors one at a time prior to assembly of each tube.
    2. Position the new fuel injector supply tubes (one at a time) between the fuel rail and the fuel injector and fully hand start and seat the fuel injector supply tube fittings onto the fuel rail and fuel injector connectors. Snug the fuel injector supply tube fittings using the inside-out step sequence (the 2 inside tubes then the 2 outside tubes).
      • Calculate the correct torque wrench setting for the following torque. Refer to the illustration.
        Fig 1: Identifying Torque Wrench Adapter Formulas
        G00468730Courtesy of FORD MOTOR CO.
      • Using a torque adapter, tighten to 2 Nm (18 lb-in).
    3. Tighten the fuel injector hold-down clamp bolt.
      • Tighten to 38 Nm (28 lb-ft).
    4. Tighten the fuel rail bolts.
      • Tighten to 31 Nm (23 lb-ft).
      5. NOTE: Pre-tighten the fuel injector fittings first, then the fuel rail fittings.
    5. Pre-tighten the fuel injector supply tube fittings.
      • Calculate the correct torque wrench setting for the following torque. Refer to the illustration.
        Fig 2: Identifying Torque Wrench Adapter Formulas
        G00468730Courtesy of FORD MOTOR CO.
      • Using a torque adapter, tighten to 12 Nm (106 lb-in).
      6. NOTE: Place a visible mark with a permanent marker on the fuel rail and fuel injector threaded connection. Turning the tube fittings one flat of the fitting is equal to 60 degrees.
    6. Final-tighten the fuel injector supply tube fittings.
      • Tighten the tube fittings 60 degrees.
  5. Attach the fuel charging wiring harness to the fuel rail.
  6. Connect the fuel injector and, if disconnected, the Fuel Rail Pressure (FRP) sensor electrical connectors.
  7. Install the LH or RH valve cover. For additional information, refer to IN-VEHICLE REPAIR .
  8. Install the fuel rail supply tube. For additional information, refer to FUEL RAIL SUPPLY TUBE - BODY OFF  or FUEL RAIL SUPPLY TUBE - BODY ON .
  9. Bleed the high-pressure fuel system. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
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