Fuel Rail: Installation

1.
- 1.
  
  Remove and discard the fuel injector O-rings.
- 2.
  
  NOTE: Note the correct orientation of the fuel injector support rings for correct installation of the fuel injector support rings.
  
  Remove and discard the fuel injector support rings.
- 3.
  
  Inspect the inlet stopper, if it is damaged or comes off discard the inlet stopper. The inlet stopper is not necessary for proper function. Ensure that any debris from the inlet stopper are removed. If the inlet stopper is intact and undamaged do not remove the inlet stopper from the fuel injector.

GFD144819

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2.

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 with narrow tip pliers.
- 2.
  
  Carefully cut the lower fuel injector Teflon ® seals.
- 3.
  
  Discard the lower fuel injector Teflon ® seals.

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3.

NOTE: Do not lubricate the new lower Teflon ® fuel injector seals.
- 1.
  
  Install the Arbor on the fuel injector tips. 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 Arbor, using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon ® seals along the Arbor.
- 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.

GFD143597

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4.

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.
  
  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.

GFD143598

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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 larger diameter 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.
  
  NOTE: Do not lubricate the new lower Teflon ® fuel injector seals.
  
  Install the new fuel injector O-rings and lubricate with clean engine oil. Refer to: Specifications .
- 3.
  
  Inspect the inlet stopper, if it is damaged or comes off discard the inlet stopper. The inlet stopper is not necessary for proper function. Ensure that any debris from the inlet stopper are removed. If the inlet stopper is intact and undamaged do not remove the inlet stopper from the fuel injector.

GFD144820

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6.

NOTE: Make sure that new fuel injector clips are installed.

Install the new the fuel injector clips.

GFD144821

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7.

NOTE: The FRP sensor must be replaced if it is removed from the fuel rail.

NOTE: The anti-rotation finger of the new fuel injector clip must slip into the groove of the fuel rail cup.

Install the fuel injectors to the fuel rail. Refer to: Fuel Rail Pressure (FRP) Sensor .

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8.

Connect the fuel injector electrical connectors.

GFD144814

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9.

NOTE: When installing the fuel rails install the right side fuel rail first.

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. Tighten the fuel rail bolts in the sequence shown.

Torque:

Stage 1: 89 lb.in (10 Nm)

Stage 2: 45 °

Fig 1: Fuel Rail Tightening Sequence

GFD144823

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10.

Attach the fuel injector wire harness electrical connector retainers and the fuel injector wire harness retainer to the fuel rail.

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11.

Connect the fuel injector wire harness connectors and the fuel rail pressure sensor wire connector.

GFD144811

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12.

Attach the fuel injector wire harness retainers to the fuel rail.

GFD144810

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13.

NOTE: Make sure that a new high pressure fuel tube, a new high pressure fuel tube bracket nut and a new high pressure fuel tube bracket bolt are installed.

NOTE: Install the new high pressure fuel tube, the high pressure fuel tube flare nuts, the new high pressure fuel tube bracket nut, the new bracket bolt and tighten finger tight at this stage. Tighten in the sequence shown.

NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas in the chart below.
- 1.
  
  Tighten the high pressure fuel tube-to-RH fuel rail tube flare nut.
  Torque:
  
  Stage 1: 89 lb.in (10 Nm)
  
  Stage 2: Tighten an additional 30 degrees or 50 Nm (37 lb-ft), whichever comes first. : 30 °
- 2.
  
  Tighten the high pressure fuel tube-to-LH fuel rail tube flare nut.
  Torque:
  
  Stage 1: 89 lb.in (10 Nm)
  
  Stage 2: Tighten an additional 30 degrees or 50 Nm (37 lb-ft), whichever comes first. : 30 °
- 3.
  
  Tighten the high pressure fuel tube-to-high-pressure fuel pump flare nut.
  Torque:
  
  Stage 1: 89 lb.in (10 Nm)
  
  Stage 2: Tighten an additional 30 degrees or 50 Nm (37 lb-ft), whichever comes first. : 30 °
- 4.
  
  Tighten the high pressure fuel tube bracket bolt.
  Torque:
  
  Stage 1: 89 lb.in (10 Nm)
  
  Stage 2: 45 °
- 5.
  
  Tighten the high pressure fuel tube bracket nut.
  Torque: 71 lb.in (8 Nm)

Fig 2: High Pressure Fuel Tube Tightening Sequence

GFD144824

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14.

Install the new coolant inlet pipe O-ring seals. Lubricate with clean engine coolant. Refer to: Specifications .

GFD144825

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15.

Install the coolant inlet pipe.

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16.

Install the new coolant crossover assembly gaskets.

GFD144827

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17.

Install the coolant crossover assembly bolts and the coolant crossover assembly. Tighten the coolant crossover assembly bolts.
Torque: 89 lb.in (10 Nm)

GFD144806

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18.

Install the intake manifold. Refer to: Intake Manifold .

19.

Connect the battery. Refer to: Battery Disconnect and Connect - Vehicles With: Single Battery . Refer to: Battery Disconnect and Connect - Vehicles With: Dual Batteries .

20.

Pressurize the fuel system. Refer to: Fuel System Pressure Release .

21.

Fill the cooling system. Refer to: Cooling System Draining, Vacuum Filling and Bleeding .