Fuel Rail Supply Tube: Installation

WARNING: This page is about a different car, the 2012 Ford Pickup, 2012 Ford F550 Super Duty, 2012 Ford F450 Super Duty, and 2012 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Use a deep-well crowfoot socket to aid in tightening the fuel rail supply tube.

Install a new fuel rail supply tube assembly in the following sequence.
1. Loosen the 4 fuel rail bolts.
2. Position the new fuel rail supply tube between the high-pressure fuel injection pump and the fuel rails. Fully hand start and seat the tube fittings to the high-pressure fuel injection pump and the fuel rails.
3. Hand start the 4 fuel rail supply tube bracket bolts and the fuel rail supply tube bracket stud bolt.
4. Tighten the 4 fuel rail bolts.
  - Tighten to 24 Nm (18 lb-ft).
5. Pre-tighten the fuel rail supply tube fittings at the fuel rails.
  - Tighten to 20 Nm (177 lb-in).
6. Pre-tighten the fuel rail supply tube fittings at the high-pressure fuel injection pump.
  - Tighten to 20 Nm (177 lb-in).
7. Tighten the fuel rail supply tube fittings at the fuel rails.
  - Tighten to 35 Nm (26 lb-ft).
8. Tighten the fuel rail supply tube fittings at the high-pressure fuel injection pump.
  - Tighten to 40 Nm (30 lb-ft).
9. Tighten the 4 fuel rail supply tube bracket bolts and the fuel rail supply tube bracket stud bolt.
  - Tighten to 10 Nm (89 lb-in).
Connect the fuel injector return hose retainer to the secondary fuel filter bracket.

Fig 1: Locating Fuel Injector Return Hose Retainer Of Secondary Fuel Filter Bracket
Courtesy of FORD MOTOR CO.
Connect the 3 fuel injector return hose retainers form the fuel rail supply tube.

Fig 2: Locating Fuel Injector Return Hose Retainers Of Fuel Rail Supply Tube
Courtesy of FORD MOTOR CO.
Connect the wiring harness retainer from the fuel rail supply tube bracket stud.

Fig 3: Locating Wiring Harness Retainer Of Fuel Rail Supply Tube Bracket Stud
Courtesy of FORD MOTOR CO.
Connect the cylinder No. 5 fuel injector electrical connector.
- Connect the engine wiring harness retainer to the LH valve cover.
  
  Fig 4: Locating Cylinder No. 5 Fuel Injector Electrical Connector And Engine Wiring Harness Retainer
  Courtesy of FORD MOTOR CO.
Install the oil fill pipe and the oil fill pipe bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 5: Locating Oil Fill Pipe And Bolt
  Courtesy of FORD MOTOR CO.
Install and connect the turbocharger coolant return tube to the coolant crossover.
Connect the coolant return tube to the turbocharger.
- Make sure the turbocharger coolant return tube is fully seated in the fitting and the retaining clip is in place.
  
  Fig 6: Locating Turbocharger Coolant Outlet Tube
  Courtesy of FORD MOTOR CO.
Install the Exhaust Gas Recirculation (EGR) valve inlet tube. For additional information, refer to Exhaust Gas Recirculation (EGR) Valve - Exploded View, 6.7L Diesel in ENGINE EMISSION CONTROL .
Using a new O-ring, install the coolant crossover-to-heater core pipe and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
- Connect the coolant crossover-to-heater core pipe quick connect fitting.
  
  Fig 7: Locating Coolant Crossover-To-Heater Core Pipe Bolts
  Courtesy of FORD MOTOR CO.
Install the fuel injection pump supply tube assembly. For additional information, refer to FUEL INJECTION PUMP SUPPLY TUBE .
Prime the high-pressure fuel system.
1. Turn the ignition key ON without cranking the engine.
2. Wait 30 seconds for the fuel conditioning module to run.
3. Turn the ignition key OFF.
4. Repeat 3 times.

NOTE: Evaluate the cooling system condition before filling the engine cooling system. Failure to follow these instructions can result in damage to the engine.

Evaluate the engine cooling system condition. For additional information, refer to Cooling System Condition Evaluation in ENGINE COOLING - DIESEL ENGINE .