Direct Injection Fuel Rail RH: Installation

WARNING: This page is about a different car, the 2021 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

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.
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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.

NOTE: The beveled opening of the Teflon® seal sizer tool goes away from the seal.

NOTE: Do not use the injector without re-forming the Teflon seal after replacing.
1. Use a soft brush to clean the inside of the re-forming tool before each use.
2. 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.
3. 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.
4. 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.
5. After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.
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NOTE: Take care to prevent foreign substances from adhering to the O-ring or the seal surface.

NOTE: Take care to prevent foreign substances from entering the fuel injector inlet.

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.
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Install the new fuel injector clips.

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NOTE: Do not re-use a fuel injector if it is dropped. Any damage to the fuel injector may cause drivability concerns or catastrophic failure of the engine.

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, then connect the fuel injector electrical connectors.

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Connect the fuel injector electrical connectors.

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1. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
  
  Install the fuel rail, push down on the fuel rail above the injectors.
2. Hand start all of the fuel rail bolts, finger tighten the fuel rail bolts so they are uniformly in light contact with fuel rail bosses.
3. Tighten the fuel rail bolts approximately 90 degrees, in the sequence shown in illustration. 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°
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NOTE: Make sure that a new high-pressure fuel tube is installed.

Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas in illustration.

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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.

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 : 30°

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Install the insulators.

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NOTE: In stage 7, 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: Do not use oil on the threads.

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

Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas in illustration.

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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 upper high-pressure fuel tube bolt to : 89 lb.in (10 Nm)

Stage 2: Tighten the upper high-pressure fuel tube bolt an additional : 30°

Stage 3: Tighten the lower high-pressure fuel tube bolt to : 89 lb.in (10 Nm)

Stage 4: Tighten the lower high-pressure fuel tube bolt an additional : 30°

Stage 5: Tighten the high-pressure fuel tube flare nuts to : 71 lb.in (8 Nm)

Stage 6: Tighten the high-pressure fuel tube flare nuts to : 89 lb.in (10 Nm)

Stage 7: Tighten the high-pressure fuel tube flare nuts an additional : 25°

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Connect the electrical connector, then attach the wiring harness retainer,

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Install the high-pressure fuel line shield, then install and tighten the high-pressure fuel line shield retainers.
Torque

: 89 lb.in (10 Nm)

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Connect the fuel injector main harness electrical connector.

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Attach the wiring harness retainer to high-pressure fuel line shield.

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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, then engage the retainer.

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Connect the high-pressure fuel pump electrical connector.

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Inspect the ignition coil-on-plug assembly for cracks, rips, or tears. Replace any damaged coil-on-plug assemblies.

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NOTE: Ensure that the ignition coil-on-plug is fully seated on the spark plug by pushing down on the boot end until it stops.

Install the ignition coil-on-plugs, then install and tighten the bolts..

Torque

: 89 lb.in (10 Nm)

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Connect the ignition coil-on-plug electrical connectors.

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Install the intake manifold. Refer to: Intake Manifold .
Pressurize the fuel system. Refer to: Fuel System Pressure Release .