Fuel Rail: Installation

WARNING: This page is about a different car, the 2024 Ford Transit-350 HD, 2024 Ford Transit-350, 2024 Ford Transit-250, and 2024 Ford Transit-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.
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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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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.
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.
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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.
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: The anti-rotation finger of the new fuel injector clip must slip into the groove of the fuel rail cup.

Install the fuel injectors to the fuel rail.

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Connect the fuel injector electrical connectors.

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Apply grease to the tip of the fuel injectors.
Material : Grease - High Temperature (WSS-M1C267-A1)

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Apply grease to the top of the fuel injector bores.
Material : Grease - High Temperature (WSS-M1C267-A1)

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NOTE: When installing the fuel rails install the right side fuel rail first.

NOTE: Make sure that new fuel rail bolts are installed.

Push down on the fuel rail above the injectors. Tighten the fuel rail bolts in the sequence shown.

Torque : Stage 1: 10 Nm Stage 2: 45deg.

Fig 1: Fuel Rail Bolts Tightening Sequence
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Attach the fuel injector wire harness electrical connector retainers and the fuel injector wire harness retainer to the fuel rail.

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Connect the fuel injector wire harness connectors and the fuel rail pressure sensor wire connector.

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Attach the fuel injector wire harness retainers to the fuel rail.

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NOTE: Make sure that a new high pressure fuel tube, a new high pressure fuel tube bracket nut and a new high pressure fuel tube bracket bolt are installed.

NOTE: Install the new high pressure fuel tube, the high pressure fuel tube flare nuts, the new high pressure fuel tube bracket nut, the new bracket bolt and tighten finger tight at this stage. Tighten in the sequence shown.

NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formula below.

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1. Tighten the high pressure fuel tube-to-RH fuel rail tube flare nut.
  Torque : Stage 1: 10 Nm Stage 2: Tighten an additional 30 degrees or 50 Nm (37 lb-ft), whichever comes first. : 30deg.
2. Tighten the high pressure fuel tube-to-LH fuel rail tube flare nut.
  Torque : Stage 1: 10 Nm Stage 2: Tighten an additional 30 degrees or 50 Nm (37 lb-ft), whichever comes first. : 30deg.
3. Tighten the high pressure fuel tube-to-high-pressure fuel pump flare nut.
  Torque : Stage 1: 10 Nm Stage 2: Tighten an additional 30 degrees or 50 Nm (37 lb-ft), whichever comes first. : 30deg.
4. Tighten the high pressure fuel tube bracket bolt.
  Torque : Stage 1: 10 Nm Stage 2: 45deg.
5. Tighten the high pressure fuel tube bracket nut.
  Torque : 8 Nm
Fig 2: High Pressure Fuel Tube Tightening Sequence
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Install the new coolant inlet pipe O-ring seals. Lubricate with clean engine coolant. Refer to: Specifications

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Install the coolant inlet pipe.

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Install the new coolant crossover assembly gaskets.

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Install the coolant crossover assembly bolts and the coolant crossover assembly. Tighten the coolant crossover assembly bolts.
Torque : 10 Nm

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Install the intake manifold. Refer to: Intake Manifold
Connect the battery. Refer to: Battery Disconnect and Connect - Vehicles With: Single Battery Refer to: Battery Disconnect and Connect - Vehicles With: Dual Batteries
Pressurize the fuel system. Refer to: Fuel System Pressure Release
Fill the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding