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Home >> Ford >> 2024 >> E-Transit Cutaway >> Repair and Diagnosis >> External Pages >> Different car >> Section 156 (Fuel Charging And Controls - 3.5L DURATEC (202KW/275PS) (Diagnosis & Testing - Removal & Installation)) >> Removal And Installation >> Direct Injection Fuel Rail RH >> Installation

Direct Injection Fuel Rail RH: Installation

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  1. 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.

    GFD838140Courtesy 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.

    GFD838141Courtesy of FORD MOTOR COMPANY
    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.
    GFD838142Courtesy 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.

    GFD838143Courtesy of FORD MOTOR COMPANY
  5. 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.

    GFD838991Courtesy of FORD MOTOR COMPANY
  6. 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.

    GFD838998Courtesy of FORD MOTOR COMPANY
  7. Connect the fuel injector electrical connectors.
    GFD838997Courtesy of FORD MOTOR COMPANY
  8. Apply grease to the tip of the fuel injectors.

    Material : Grease - High Temperature (WSS-M1C267-A1)

    GFD838146Courtesy of FORD MOTOR COMPANY
  9. Apply grease to the top of the fuel injector bores.

    Material : Grease - High Temperature (WSS-M1C267-A1)

    GFD838147Courtesy of FORD MOTOR COMPANY
  10. 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.

    GFD839001Courtesy of FORD MOTOR COMPANY
  11. Connect the fuel injector main harness electrical connector, then attach the electrical connector retainer to the rear of cylinder head.
    GFD838995Courtesy of FORD MOTOR COMPANY
  12. Install the direct injection fuel rail LH. Refer to: Direct Injection Fuel Rail LH 
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