Fuel Rail - 3.5L GTDI: Installation

WARNING: This page is about a different car, the 2013 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: A clean working environment is essential to prevent dirt or foreign material contamination.

NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.

NOTE: Do not use compressed air to clean the tip of the fuel injector.

NOTE: Do not use a brush to clean the tip of the fuel injector.

Using the Fuel Injector Brush, clean the fuel injector bore in the cylinder head. Special Tool(s): 310-205.
NOTE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur.

NOTE: Be very careful when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.
1. Pull the lower Teflon® seal away from the injector.
2. Carefully cut and discard the lower fuel injector Teflon® seals.
Place the Teflon® Seal Sizer, knurled side out, over the fuel injector tip until the fuel injector seal recess is exposed.
1. Special Tool(s): Sizer, Teflon® Seal 303-1567.
2. Special Tool(s): Seal Installer, Fuel Injector 310-207.
3. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
  
  NOTE: Make sure that new lower fuel injector Teflon® seals are installed.
4. Special Tool(s): Seal Installer, Fuel Injector 310-207.
NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the seal.

NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion.

Special Tool(s): Sizer, Teflon® Seal 303-1567.
NOTE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.

NOTE: Make sure that new upper fuel injector O-ring seals, upper fuel injector O-ring seal support rings and fuel injector retainer clips are installed.

Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-30 Super Premium Motor Oil (Canada) XO-5W30-QSP (US); CXO-5W30-LSP12 (Canada); or equivalent.
NOTE: LH shown in illustration, RH similar.

NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.
NOTE: It is very important to note the routing of the fuel charge wiring harnesses on the fuel rails and index-mark the location of the tie straps prior to removal or damage may occur to the wire harnesses during installation. The illustration details the correct fuel charge wire harness routing and tie strap positioning for installation.

Install the fuel charge wire harnesses and tie straps to the index-marked locations on the fuel rails. Start by attaching the first tie strap farthest down the wire harness and continue to the connector end of the harness, leaving ample slack between the fuel injectors.
NOTE: It is very important to visually inspect the routing of the fuel charge wire harness to make sure that they will not be pinched or damaged between the fuel rail and the cylinder head during installation.

NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

NOTE: Make sure that 6 new fuel rail bolts are installed.

NOTE: Tighten the bolts in a method that draws the fuel rail evenly to the head, preventing a rocking motion.

Tighten the 6 fuel rail bolts in the following 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in) in the sequence shown in illustration.
- Stage 2: Tighten an additional 45 degrees in the sequence shown in illustration.
NOTE: It is very important to visually inspect the routing of the fuel charge wire harness to make sure that they will not be pinched or damaged between the fuel rail and the cylinder head during installation.

NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

NOTE: Make sure that 6 new fuel rail bolts are installed.

NOTE: Tighten the bolts in a method that draws the fuel rail evenly to the head, preventing a rocking motion.

Tighten the 6 fuel rail bolts in the following 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in) in the sequence shown in illustration.
- Stage 2: Tighten an additional 45 degrees in the sequence shown in illustration.

NOTE: To install, apply clean engine oil to the threads of the 3 high-pressure fuel tube flare nuts. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-30 Super Premium Motor Oil (Canada) XO-5W30-QSP (US); CXO-5W30-LSP12 (Canada); or equivalent.

NOTE: Calculate the correct torque wrench setting for the following torque. Refer to the Torque Wrench Adapter Formulas.

Fig 1: Torque Wrench Adapter Formulas
Courtesy of FORD MOTOR CO.

Install the high-pressure fuel tube and tighten the 3 flare nuts in the following 3 stages.
- Stage 1: Tighten to 32 Nm (24 lb-ft).
- Stage 2: Wait 10 minutes to minimize pre-stress.
- Stage 3: Tighten to 32 Nm (24 lb-ft).

Tighten to 8 Nm (71 lb-in).

NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.
Install the intake manifold, REFER to ENGINE - 3.5L GTDI .
Connect the battery ground cable, REFER to BATTERY DISCONNECT for connection procedure.
Pressurize the fuel system pressure, REFER to FUEL SYSTEM PRESSURE RELEASE , step 7.