Fuel Rail: Installation

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

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 Arbor, 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.
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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 the Teflon® seal sizer tool.
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NOTE: Make sure that new fuel injector support rings and new fuel injector O-ring seals are installed.
1. NOTE: The large diameter step of the backup ring must go up towards the new O-ring seal. Improperly installed backup rings may cause the fuel system to leak.
  
  Install the new the fuel injector support rings.
2. 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.
  
  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. NOTE: Make sure that new fuel injector clips are installed.
  
  Install the new the fuel injector clips.
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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 .

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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 injectors. Install and tighten the fuel rail bolts in sequence shown.

Torque

: 17 lb.ft (23 Nm)

Fig 1: Fuel Rail Bolt Tightening Sequence
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Connect the fuel injector electrical connectors.

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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.

Install the new 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: 124 lb.in (14 Nm) Stage 2: 177 lb.in (20 Nm) Stage 3: 20°

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Install the Ignition Coil-On-Plugs. Refer to: Ignition Coil-On-Plug .
Reconnect battery negative cable. Refer to: Battery Disconnect and Connect .
Pressurize the fuel system. Refer to: Fuel System Pressure Release .