Fuel Rail: Installation

WARNING: This page is about a different car, the 2018 Ford EcoSport. However, it is still accessible from the selected car via links, so may be relevant.

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

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® seal.
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NOTE: Do not lubricate the new lower Teflon® fuel injector seal.
1. Install the Arbor on the fuel injector tip. 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® seal onto the Arbor, using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon® seal along the Arbor.
3. Using the Pusher Tool, slide the Teflon® seal off of the Teflon® Seal Guide and into the groove on the fuel injector. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.
4. Remove the special tools.
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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. 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.
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NOTE: Make sure that new fuel injector support rings and new fuel injector O-ring seals are installed.
1. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
  
  Install the new fuel injector O-ring seals and lubricate with clean engine oil. Refer to: Specifications .
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. The fuel injector support ring.
6. The lower side of the support ring has the narrow surface area.
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NOTE: Make sure that new fuel injector clips are installed.

Install the new the fuel injector clips.

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

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

Install the fuel injectors to the fuel rail.

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

NOTE: No sudden impact force is allowed.

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

Torque: 18 lb.ft (25 Nm)

Fig 1: Fuel Rail Location W/ Bolt Tightening Sequence
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Connect the fuel rail pressure sensor electrical connector, then connect the fuel injector electrical connectors.

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Install the fuel rail insulator, then attach the fuel charge wire harness retainers to the fuel rail.

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Install the crash bracket, then install and tighten the bolt and the nuts.
Torque: Tighten the bolt to : 177 lb.in (20 Nm) Tighten the nuts to : 106 lb.in (12 Nm)

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NOTE: Calculate the correct torque wrench setting for the following torque

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Position a new high-pressure fuel tube and hand start the flare nuts. Loosely install the high pressure fuel tube bracket bolts.

Tighten the high pressure fuel tube flare nuts in the following 2 stages.
Torque: Stage 1: Tighten the high pressure fuel tube flare nuts first to: : 89 lb.in (10 Nm) Stage 2: Tighten an additional: : 30 deg.
Tighten the high-pressure fuel tube bracket bolts.
Torque: 89 lb.in (10 Nm)

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

Install the fuel injection pump noise insulator.

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Install the accessory drive belt tensioner. Refer to: Accessory Drive Belt Tensioner .
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 .