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Home >> Ford >> 2022 >> Transit Connect Titanium, Gas/Ethanol >> Repair and Diagnosis >> External Pages >> Different car >> Section 419 (Fuel Charging And Controls - 5.0L 32V Ti-VCT) >> Removal And Installation >> Direct Injection Fuel Rail RH >> Installation

Direct Injection Fuel Rail RH: Installation

WARNING: This page is about a different car, the 2020 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.
    1. Remove and discard the fuel injector O-ring seals.
    2. 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 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.
    GFD459195Courtesy of FORD MOTOR COMPANY
  2. 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.

    GFD462514Courtesy of FORD MOTOR COMPANY
  3. 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.

    GFD462515Courtesy of FORD MOTOR COMPANY
  4. 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.

    GFD462516Courtesy of FORD MOTOR COMPANY
  5. NOTE: Make sure that NEW fuel injector support rings and NEW fuel injector O-ring seals are installed.

    1. Install the new fuel injector O-rings. The O-rings are pre-lubricated, NO ADDITIONAL lubricant is required.
    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. Fuel injector support ring.
    6. The lower side of the support ring has the narrow surface area.

    GFD459200Courtesy of FORD MOTOR COMPANY
  6. Install the NEW fuel injector clips.
    GFD459201Courtesy of FORD MOTOR COMPANY
  7. 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 and then connect the fuel injector electrical connectors.

    GFD461240Courtesy of FORD MOTOR COMPANY
  8. Connect the fuel injector electrical connectors.
    GFD462517Courtesy of FORD MOTOR COMPANY
    • NOTE: Do not lubricate the NEW lower Teflon® fuel injector seals.

      Install the fuel rail, push down on the fuel rail above the injectors.

    • Hand start all of the fuel rail bolts and finger tighten the fuel rail bolts so they are uniformly in light contact with fuel rail bosses.

    • Tighten the fuel rail bolts approximately 90 degrees, in the sequence shown. Repeat to evenly draw down the fuel rail, until the fuel rail bosses are in contact with the cylinder head.

      Torque:Stage 1: Tighten the fuel rail bolts in the sequence shown to : 89 lb.in (10 Nm) | Stage 2: Tighten the fuel rail bolts in the sequence shown to : 21 lb.ft (28 Nm) | Stage 3: Tighten the fuel rail bolts in the sequence shown an additional : 25 deg.

    GFD462518Courtesy of FORD MOTOR COMPANY
  10. Install the insulators.
    GFD461117Courtesy of FORD MOTOR COMPANY
  11. NOTE: In stage 3, if the torque required to tighten any flare nut on the new high-pressure fuel tube reaches or exceeds 55 lb.ft (50 Nm), then that high pressure fuel tube must be discarded and replaced with another new high-pressure fuel tube.
    NOTE: Make sure that a new high-pressure fuel tube is installed.
    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 CO.

    Install the high-pressure fuel tube and tighten the flare nuts finger tight, then tighten the flare nuts in the following 3 stages.

    Torque:Stage 1: Tighten the high-pressure fuel tube flare nuts to : 71 lb.in (8 Nm) | Stage 2: Tighten the high-pressure fuel tube flare nuts to : 89 lb.in (10 Nm) | Stage 3: Tighten the high-pressure fuel tube flare nuts an additional : 25 deg.

    GFD460883Courtesy of FORD MOTOR COMPANY
  12. NOTE: In stage 6, if the torque required to tighten any flare nut on the new high-pressure fuel tube reaches or exceeds 37 lb.ft (50 Nm), then that high pressure fuel tube must be discarded and replaced with another new high-pressure fuel tube.
    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 CO.
    NOTE: Make sure that a new high-pressure fuel tube is installed.

    Install the high-pressure fuel tube and retainers, tighten the high-pressure fuel tube flare nuts and retainers finger tight.

    Torque:Stage 1: Tighten the high-pressure fuel tube bolt to : 89 lb.in (10 Nm) | Stage 2: Tighten the high-pressure fuel tube stud-bolt to : 89 lb.in (10 Nm) | Stage 3: Tighten the high-pressure fuel tube stud-bolt an additional : 30 deg. | Stage 4: Tighten the high-pressure fuel tube flare nuts to : 71 lb.in (8 Nm) | Stage 5: Tighten the high-pressure fuel tube flare nuts to : 89 lb.in (10 Nm) | Stage 6: Tighten the high-pressure fuel tube flare nuts an additional : 25 deg.

    GFD461311Courtesy of FORD MOTOR COMPANY
  13. Install the high-pressure fuel line shield, then install and tighten the high-pressure fuel line shield retainers.

    Torque: 89 lb.in (10 Nm)

    GFD461157Courtesy of FORD MOTOR COMPANY
  14. Connect the fuel injector main harness electrical connector.
    GFD462508Courtesy of FORD MOTOR COMPANY
  15. Attach the wiring harness retainers to high-pressure fuel line shield.
    GFD462507Courtesy of FORD MOTOR COMPANY
  16. 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, then engage the retainer.

    GFD461155Courtesy of FORD MOTOR COMPANY
  17. Connect the high-pressure fuel pump electrical connector.
    GFD461154Courtesy of FORD MOTOR COMPANY
  18. Install the intake manifold. Refer to: Intake Manifold .
  19. Pressurize the fuel system. Refer to: Fuel System Pressure Release .
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