Fuel Rail: Installation

NOTE: A clean working environment is essential to prevent dirt or foreign material contamination.

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.

NOTE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.
1. Pull the lower Teflon® seal away from the injector.
2. Carefully cut and discard the lower fuel injector Teflon® seals.
NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
1. Special Tool(s): 310-207.
2. NOTE: Once the Teflon® seal is installed on the Teflon® Seal Guide 310-207 (part of the Fuel Injector Seal Installer), 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.
  
  Special Tool(s): 310-207.
3. Using the Pusher Tool 310-207 (part of the Fuel Injector Seal Installer), slide the Teflon® seals off of the Teflon® Seal Guide and into the groove on the fuel injectors. Special Tool(s): 310-207.
NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion.
1. NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.
  
  Some Teflon® seal massaging with your fingers before the Teflon® seal sizer tool is installed will aid in installing the Teflon® seal sizer tool.
2. Position the Teflon® seal sizer tool 303-1567 with the larger opening towards the Teflon® seal. Push while turning the Teflon® seal sizer tool 180 degrees. Special Tool(s): 303-1567.
3. Once the Teflon® seal sizer tool 303-1567 is installed, check and make sure the Teflon® seal is in the sizing portion of the Teflon® seal sizer tool. After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.
NOTE: Use new fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.

NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

NOTE: Make sure that new upper fuel injector O-ring seals, new upper fuel injector O-ring seal support rings and new fuel injector retainer clips are installed.

Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (US).
NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.

NOTE: The fuel rail pressure sensor must be replaced if it is removed from the fuel rail. Refer to ELECTRONIC ENGINE CONTROLS .
NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

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

NOTE: Push down on the fuel rail face above the injectors.

Tighten the 5 fuel rail bolts in the following 2 stages.
- Stage 1: Tighten to 8 Nm (71 lb-in) in the sequence shown in illustration.
- Stage 2: Tighten an additional 26 degrees in the sequence shown in illustration.
NOTE: Only tighten the 2 high pressure fuel tube flare nuts finger tight at this stage.

NOTE: Only tighten the 2 high pressure fuel tube bracket bolts finger tight at this stage.
1. NOTE: Make sure that a new high pressure fuel tube is installed.
2. NOTE: Calculate the correct torque wrench setting for the following torque. Refer to the Torque Wrench Adapter Formulas illustration.
  
  Fig 1: Torque Wrench Adapter Formulas
  Courtesy of FORD MOTOR CO.
  - Stage 1: Using a torque adapter, tighten to 15 Nm (133 lb-in).
  - Stage 2: Tighten an additional 30 degrees.
3. Tighten to 10 Nm (89 lb-in).
NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.
Install the intake manifold, refer to ENGINE - 2.0L GTDI .
1. Tighten to 5 Nm (44 lb-in).
2. Refer to FUEL SYSTEM - GENERAL INFORMATION .
Install the ACL outlet pipe, refer to INTAKE AIR DISTRIBUTION & FILTERING .
Connect the battery ground cable, refer to BATTERY, MOUNTING AND CABLES .
Pressurize the fuel system, refer to FUEL SYSTEM - GENERAL INFORMATION .