Direct Injection Fuel Rail LH: 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.

NOTE: Note the correct orientation of the fuel injector support rings, to insure the 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.
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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. 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.
2. 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.
3. 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.
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.
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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. Install the new fuel injector O-ring.
3. Install the new the fuel injector clips.
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NOTE: The anti-rotation finger of the fuel injector 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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Install the fuel rail, push down on the fuel rail above the injectors, then tighten the fuel rail bolts in the following 2 stages, in the sequence shown.
Torque : Stage 1: Tighten to: : 10 Nm Stage 2: Tighten an additional: : 45deg.

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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 (75 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 below.

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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 to: : 7 Nm Stage 2: Tighten to: : 10 Nm Stage 3: Tighten an additional: : 30deg.

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Connect the fuel injector main harness electrical connector, then attach the electrical connector retainer to the rear of cylinder head.

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

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NOTE: Make sure that a new high-pressure fuel tube and a new retaining nut is installed.
1. Install the new high-pressure fuel tube and tighten the flare nuts finger tight.
2. Install new the high-pressure fuel tube retaining nut finger tight.
3. 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 (75 Nm), then that high pressure fuel tube must be discarded and replaced with another new high-pressure fuel tube.
  
  Tighten the high-pressure fuel tube flare nuts in the following 3 stages.
  
  Torque : Stage 1: Tighten to: : 9 Nm Stage 2: Tighten to: : 10 Nm Stage 3: Tighten an additional: : 30deg.
4. Tighten the high-pressure fuel pump to fuel rail high-pressure fuel tube retaining nut.
  Torque : 8 Nm
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Attach the wire harness retainer.

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Install the lower intake manifold. Refer to: Lower Intake Manifold