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Home >> Ford >> 2020 >> Fusion Titanium Hybrid >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 38 (Fuel Charging And Controls - 1.5L ECOBOOST (118KW/160PS) - I4) >> Removal And Installation >> Fuel Rail >> Installation

Fuel Rail: Installation

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  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.

    GFD481747Courtesy 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 with narrow tip pliers.
    2. Carefully cut, remove and discard the lower fuel injector Teflon® seals.

    GFD481447Courtesy 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.
    4. Remove the special tools.

    GFD481449Courtesy of FORD MOTOR COMPANY
  4. 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. 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.

    GFD481450Courtesy of FORD MOTOR COMPANY
  5. NOTE: Use new 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 the fuel injector support rings as noted during removal.

    • Install the new fuel injector O-rings and lubricate with clean engine oil.

    GFD481748Courtesy of FORD MOTOR COMPANY
  6. Install the new the fuel injector clips.
    GFD481749Courtesy of FORD MOTOR COMPANY
  7. NOTE: The FRP sensor must be replaced only if it is removed from the fuel rail.
    NOTE: The fuel injector clip must lock into the slot of the fuel rail cup.

    Install the fuel injectors to the fuel rail, then connect the fuel injector electrical connectors. Refer to: Fuel Rail Pressure (FRP) Sensor .

    GFD481743Courtesy of FORD MOTOR COMPANY
  8. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
    NOTE: Only tighten the 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 the sequence shown.

      Torque: 17 lb.ft (23 Nm)

    • Connect the fuel injector main wire harness electrical connector.

    GFD481750Courtesy of FORD MOTOR COMPANY
  9. NOTE: Make sure that a new high pressure fuel tube is installed.
    NOTE: Only tighten the 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.
    G00468730Courtesy of FORD MOTOR COMPANY

    Tighten the high-pressure fuel tube flare nuts in the following 3 stages.

    Torque: Stage 1: 15 lb.ft (21 Nm) - Stage 2: Wait 5 min - Stage 3: 15 lb.ft (21 Nm)

    GFD481751Courtesy of FORD MOTOR COMPANY
  10. Attach the wire harness retainers and connect the FRP electrical connector.
    GFD481740Courtesy of FORD MOTOR COMPANY
  11. Install the ignition coil-on-plugs. Refer to: Ignition Coil-On-Plug .
  12. Connect the battery. Refer to: Battery Disconnect and Connect .
  13. Pressurize the fuel system. Refer to: Fuel System Pressure Release .
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