Fuel Rail: Installation

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

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-ring seals and the fuel injector support rings.

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

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.
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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.

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.
1. Install the new the fuel injector support rings.
2. Install the new fuel injector O-ring seals and lubricate with clean engine oil.
  Material
  
  : Motorcraft® SAE 5W-30 Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)
3. 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.

Install the fuel rail, push down on the fuel rail above the injectors. Install and tighten the fuel rail bolts in the sequence shown and in the following 2 stages.

Torque

:Stage 1: 71 lb.in (8 Nm) Stage 2: 26°

Fig 1: Fuel Rail Bolt Tightening Sequence
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1. Connect the fuel injector electrical connectors.
2. Install the fuel rail insulator.
3. Install the retainers.
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NOTE: Only tighten the high pressure fuel tube flare nuts finger tight at this stage.

NOTE: Only tighten the high pressure fuel tube bracket bolts finger tight at this stage.

Install the following items:

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

Install the new high-pressure fuel tube.

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

Tighten the high-pressure fuel tube flare nuts in the following 2 stages.

Torque

:Stage 1: 133 lb.in (15 Nm) Stage 2: 30°

Tighten the high-pressure fuel tube bracket bolt.
Torque

: 89 lb.in (10 Nm)

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Attach the EVAP canister purge valve to the EVAP canister purge valve bracket, connect the EVAP canister purge valve electrical connector.

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NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.
1. Install the fuel injection pump noise insulator.
2. Connect the fuel injection pump electrical connector.
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Install the following items:
1. Install the air cleaner outlet pipe and tighten the clamps.
  Torque
  
  : 44 lb.in (5 Nm)
2. Install and tighten the air cleaner outlet pipe bolt.
  Torque
  
  : 44 lb.in (5 Nm)
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Install the intake manifold. Refer to: Intake Manifold .
Reconnect the battery. Refer to: Battery Disconnect and Connect .
Pressurize the fuel system. Refer to: Fuel System Pressure Release .