Fuel Rail: Installation

WARNING: This page is about a different variant/trim than selected.

1.

NOTE: Note the correct orientation of the fuel injector support rings for correct installation of the new fuel injector support rings.

Remove and discard the fuel injector O-rings. Remove and discard the fuel injector support rings.

GFD139808

Courtesy of FORD MOTOR COMPANY

2.

NOTE: Use care when removing the lower Teflon ® seals, not to scratch, nick or gouge the fuel injectors.

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.
- 1.
  
  Pull the lower Teflon ® seal away from the injector.
- 2.
  
  Carefully cut and discard the lower fuel injector Teflon ® seals.

GFD139809

Courtesy of FORD MOTOR COMPANY

3.

NOTE: Do not lubricate the new lower Teflon ® fuel injector seals.
- 1.
  
  Install the Arbor (part of the Fuel Injector Seal Installer) 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.

GFD138956

Courtesy of FORD MOTOR COMPANY

4.

NOTE: Make sure the Teflon ® seal is fully seated in the groove on the fuel injector before sizing the Teflon ® seal.
- 1.
  
  Massage and warm the Teflon ® seal with your fingers before the Teflon ® seal sizer tool is installed. This 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 the Teflon ® seal sizer tool.

GFD138957

Courtesy of FORD MOTOR COMPANY

5.

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

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.
- 1.
  
  Install the new the fuel injector support rings.
- 2.
  
  Install the new fuel injector O-rings and lubricate with clean engine oil.
  Material: Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
- 3.
  
  Install the new the fuel injector clips.

GFD138958

Courtesy of FORD MOTOR COMPANY

6.

NOTE: The FRP sensor must be replaced if it is removed from the fuel rail.

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 .

GFD139810

Courtesy of FORD MOTOR COMPANY

7.

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

NOTE: Only tighten the 3 fuel rail bolts finger tight at this stage.

Install the fuel rail, push down on the fuel rail above the fuel injectors, then install and tighten the fuel rail bolts. Tighten 1 turn at a time in the sequence shown.

Torque: 17 lb.ft (23 Nm)

Fig 1: Fuel Rail Tightening Sequence

GFD139811

Courtesy of FORD MOTOR COMPANY

8.

Connect the fuel injector and the FRP sensor electrical connectors.

GFD139805

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9.

NOTE: Make sure that a new component is installed.

NOTE: Only tighten the 2 high pressure fuel tube flare nuts finger tight at this stage.

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

Install the new high-pressure fuel tube, then tighten the high-pressure fuel tube flare nuts in the following 3 stages.

Torque:

Stage 1: 124 lb.in (14 Nm)

Stage 2: 177 lb.in (20 Nm)

Stage 3: 20 °

GFD139798

Courtesy of FORD MOTOR COMPANY

10.

Install the ignition coil-on-plugs. Refer to: Ignition Coil-On-Plug .

11.

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

12.

Pressurize the fuel system. Refer to: Fuel System Pressure Release .