Fuel Rail: Installation

Courtesy of FORD MOTOR COMPANY

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.

Pull the lower Teflon ® seal away from the injector.

Carefully cut and discard the lower fuel injector Teflon ® seals.

Courtesy of FORD MOTOR COMPANY

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

Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.
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.

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.

Courtesy of FORD MOTOR COMPANY

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.
Courtesy of FORD MOTOR COMPANY
NOTE: The large diameter step of the backup ring must go up towards the new O-ring seal. Improperly installed backup rings may cause the fuel system to leak.

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 Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

Courtesy of FORD MOTOR COMPANY

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.

Refer to: Fuel Rail Pressure (FRP) Sensor .

Courtesy of FORD MOTOR COMPANY
NOTE: Do not lubricate the new lower Teflon ® fuel injector seals.

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

Torque:

Stage 1: 71 lb.in (8 Nm)

Stage 2: 26 °

Fig 1: Fuel Rail Tightening Sequence
Courtesy of FORD MOTOR COMPANY
Courtesy of FORD MOTOR COMPANY

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

NOTE: Only tighten the high pressure fuel tube bracket bolt and nut finger tight at this stage.

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 in the chart below.

Courtesy of FORD MOTOR COMPANY

Torque:

Stage 1: 62 lb.in (7 Nm)

Stage 2: 133 lb.in (15 Nm)

Stage 3: 30 °

Torque: 89 lb.in (10 Nm)
Torque: 150 lb.in (17 Nm)

Courtesy of FORD MOTOR COMPANY

NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.

Courtesy of FORD MOTOR COMPANY
Install the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe
Install the intake manifold. Refer to: Intake Manifold .
Reconnect the battery. Refer to: Battery Disconnect and Connect .
Pressurize the fuel system. Refer to: Fuel System Pressure Release .