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Home >> Ford >> 2021 >> Explorer Limited Hybrid, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 35 (Fuel Charging And Controls - 2.3L ECOBOOST (201KW/273PS)) >> Removal And Installation >> Fuel Rail >> Installation

Fuel Rail: Installation

WARNING: This page is about a different variant/trim than selected.
  1. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

    1. Install the Teflon® Seal Guide onto 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® seals onto the Teflon® Seal Guide, using the Pusher Tool, slide the Teflon® seals along the Teflon® Seal Guide.

    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.

    GFD513213Courtesy of FORD MOTOR COMPANY
  2. 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. NOTE: The beveled opening of the Teflon® seal sizer tool goes away from the seal.

      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.

    GFD513214Courtesy of FORD MOTOR COMPANY
  3. NOTE: Make sure that new fuel injector support rings and new fuel injector O-ring seals are installed.

    1. 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.

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

      Install the new fuel injector O-rings.

    3. Install the new the fuel injector clips.

    GFD513215Courtesy of FORD MOTOR COMPANY
  4. 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.

    GFD513207Courtesy of FORD MOTOR COMPANY
  5. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

    • NOTE: No sudden impact force is allowed.

      Press the fuel rail down into the cylinder head injector bores by hand, then install and hand start new bolts 3 and 4.

    • Release the force before tightening.

    • Install the remaining new bolts. Tighten all of the fuel rail bolts in the sequence shown and in the following 5 stages.

      Torque: Stage 1: Tighten to: : 89 lb.in (10 Nm) - - Stage 2: Back off to: : 0 lb.in (0 Nm) - - Stage 3: Wait 5s Stage 4: Tighten to: : 124 lb.in (14 Nm) - - Stage 5: Tighten an additional: : 30°

    Fig 1: Fuel Rail Tightening Sequence
    GFD513216Courtesy of FORD MOTOR COMPANY
    • Install the fuel rail wire harness, connect the wire harness retainer to the fuel rail.

    • Connect the fuel rail pressure sensor electrical connector.

    GFD513205Courtesy of FORD MOTOR COMPANY
    • Install the fuel rail insulator.

    • Attach the wire harness retainers to the fuel rail.

    GFD513204Courtesy of FORD MOTOR COMPANY
  8. NOTE: Align molded pin on bottom of the shield and install into boss in location.
    NOTE: An enhanced hexalobular or torx plus bit must be used.

    Install the shield, then install and tighten the bolt.

    Torque: 18 lb.ft (25 Nm)

    GFD513203Courtesy of FORD MOTOR COMPANY
  9. NOTE: Make sure that a new high-pressure fuel tube is installed.

    1. Install the new high-pressure fuel tube and the bracket bolt and studbolt, then tighten the high pressure fuel tube flare nuts and the bracket bolt and studbolt only finger tight at this stage.
    2. Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas below.
      G00468730Courtesy of FORD MOTOR COMPANY

      Torque: High pressure fuel tube flare nuts, : Stage 1: Tighten to: : 62 lb.in (7 Nm) - - Stage 2: Tighten to: : 89 lb.in (10 Nm) - - Stage 3: Tighten an additional: : 38° High-pressure fuel tube bracket bolt and studbolt, tighten to: : 97 lb.in (11 Nm)

    GFD513217Courtesy of FORD MOTOR COMPANY
  10. Install the bracket, then install and tighten the nuts.

    Torque: 97 lb.in (11 Nm)

    GFD513201Courtesy of FORD MOTOR COMPANY
  11. Connect the electrical connector, then attach the wiring harness retainers.
    GFD513200Courtesy of FORD MOTOR COMPANY
  12. NOTE: When removing or installing the high-pressure fuel pump noise insulator, spreading the openings will reduce the risk of damage.

    Install the high-pressure fuel pump noise insulator.

    GFD513199Courtesy of FORD MOTOR COMPANY
  13. Connect the high-pressure fuel pump electrical connector and the sensor connector.
    GFD513198Courtesy of FORD MOTOR COMPANY
  14. Install the intake manifold. Refer to: Intake Manifold .
  15. Connect the battery. Refer to: Battery Disconnect and Connect .
  16. Pressurize the fuel system. Refer to: Fuel System Pressure Release .
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