Fuel Rail: Installation

WARNING: This page is about a different car, the 2015 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

Both fuel rails

1.

NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
- 1.
  
  Install the Arbor on the fuel injector tips.
  Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.
- 2.
  
  NOTE: Once the Teflon® seal is installed on the Teflon® Seal Guide, it should immediately be installed onto the fuel injector to avoid excessive expansion of the Teflon® seal.
  
  NOTE: Make sure that new lower fuel injector Teflon® seals are installed.
  
  Install the new Teflon® seals onto the Arbor, using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon® seals along the Arbor.
- 3.
  
  Using the Pusher Tool, slide the Teflon® seals off of the Teflon® Seal Guide and into the groove on the fuel injectors.
  Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.

Courtesy of FORD MOTOR COMPANY

2.

NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.
- 1.
  
  Some Teflon® seal massaging with your fingers before the Teflon® seal sizer tool is installed will aid in installing the Teflon® seal sizer tool.
- 2.
  
  Position the Teflon® seal sizer tool with the larger opening towards the Teflon® seal. Push while turning the Teflon® seal sizer tool 180 degrees.
  Use Special Service Tool: 303-1567 Sizer, Teflon Seal.
- 3.
  
  Once the Teflon® seal sizer tool is installed, check and make sure the Teflon® seal is in the sizing portion of the Teflon® seal sizer tool.
- 4.
  
  After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.

Courtesy of FORD MOTOR COMPANY

3.

NOTE: Make sure that new fuel injector support rings and new fuel injector O-ring seals are installed.
- 1.
  
  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 old O-ring seals.
  
  NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
  
  Install the new fuel injector O-rings and lubricate with clean engine oil.
  
  Material
  
  : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)
- 2.
  
  NOTE: The new the fuel injector support rings must be installed in the correct orientation with the wide surface area facing up against the fuel injector O-ring seals. Improperly installed support rings may cause the fuel system to leak.
  
  Install the new the fuel injector support rings.
- 3.
  
  Inspect the inlet stopper, if it is damaged or comes off then discard the inlet stopper. The inlet stopper is not needed for proper function. Ensure that any debris from the inlet stopper are removed. If the inlet stopper is intact and undamaged do not remove the inlet stopper from the fuel injector.
- 4.
  
  The upper side of the support ring has the wide surface area.
- 5.
  
  Fuel injector support ring.
- 6.
  
  The lower side of the support ring has the narrow surface area.

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4.

NOTE: Make sure that new fuel injector clips are installed.

Install the new the fuel injector clips.

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Right fuel rail

5.

NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.

Install the fuel injectors to the fuel rail.

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6.

Connect the fuel injector electrical connectors.

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7.

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

Install the RH fuel rail, push down on the fuel rail above the injectors, then install and tighten the RH fuel rail bolts.

Torque

: 18 lb.ft (24 Nm)

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8.

NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas in Fig 1.

NOTE: Make sure that a new high-pressure fuel pump-to-fuel rail high-pressure fuel tube is installed.

Install the high-pressure fuel pump-to-fuel rail high-pressure fuel tube and tighten the flare nuts finger tight, then tighten the flare nuts in the following 3 stages.

Torque:

Stage 1: 62 lb.in (7 Nm)

Stage 2: 89 lb.in (10 Nm)

Stage 3: 25°

Fig 1: Torque Wrench Adapter Formulas

Courtesy of FORD MOTOR CO.

Courtesy of FORD MOTOR COMPANY

Left fuel rail

9.

NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.
- Install the fuel injectors to the fuel rail.
- Refer to: FUEL RAIL PRESSURE (FRP) SENSOR .

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10.

Connect the fuel injector electrical connectors.

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11.

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

Install the LH fuel rail, push down on the LH fuel rail above the injectors, then install and tighten the LH fuel rail bolts.

Torque

: 18 lb.ft (24 Nm)

Courtesy of FORD MOTOR COMPANY

Both fuel rails

12.

NOTE: Make sure that a new fuel rail-to-fuel rail high-pressure fuel tube is installed.

NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas in Fig 2.

Install the fuel rail-to-fuel rail high-pressure fuel tube and tighten the flare nuts finger tight, then tighten the flare nuts in the following 3 stages.

Torque:

Stage 1: 62 lb.in (7 Nm)

Stage 2: 89 lb.in (10 Nm)

Stage 3: 25°

Fig 2: Torque Wrench Adapter Formulas

Courtesy of FORD MOTOR CO.

Courtesy of FORD MOTOR COMPANY

13.

NOTE: When removing or installing the high-pressure fuel pump noise insulator, spreading the openings will reduce the risk of damage.

Install the high-pressure fuel pump noise insulator.

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14.

Install the intake manifold. Refer to: INTAKE MANIFOLD .

15.

Connect the battery. Refer to: Battery Disconnect and Connect .

16.

Pressurize the fuel system. Refer to: FUEL SYSTEM PRESSURE RELEASE .