Fuel Rail: Installation

NOTE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.

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® seals.
NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
1. 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.
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 .
NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion.

NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.
1. 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 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. After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.
NOTE: Use 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.

Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
NOTE: The FRP sensor must be replaced if it is removed from the fuel rail.

NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.
NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

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

Push down on the fuel rail above the injectors.

Torque :

Stage 1: 71 lb.in (8 Nm)

Stage 2: 26°
NOTE: Only tighten the 2 high pressure fuel tube flare nuts finger tight at this stage.

NOTE: Only tighten 2 high pressure fuel tube bracket bolts finger tight at this stage.

Install the following items:
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 using the Torque Wrench Adapter Formulas.
  
  Torque :
  
  Stage 1: 133 lb.in (15 Nm)
  
  Stage 2: 30°
3. Torque : 89 lb.in (10 Nm)
NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.
Install the following items:
1. Torque : 44 lb.in (5 Nm)
2. Torque : 44 lb.in (5 Nm)
Refer to: INTAKE MANIFOLD .
Refer to: BATTERY DISCONNECT AND CONNECT .
Refer to: FUEL SYSTEM PRESSURE RELEASE .