Fuel Rail: Installation

• 1.
  
  Install the Arbor onto the fuel injector tips.

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

• 2.
  
  
  NOTE: Make sure that new lower fuel injector Teflon® seals are installed.

  Install the new Teflon® seals onto the Arbor, using the Pusher Tool slide the Teflon® seals along the Arbor.

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

• 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.

• 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.

  Use Special Service Tool: 303-1567 Sizer, Teflon Seal.

• 4.
  
  After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.

  Use Special Service Tool: 303-1567 Sizer, Teflon Seal.

• 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.
  
  
  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.

  Install the new fuel injector O-ring seals and lubricate them with clean engine oil.

• 3.
  
  Install the new the fuel injector clips.

Install the fuel injectors to the fuel rail. Refer to: FUEL RAIL PRESSURE (FRP) SENSOR - 2.0L EcoBoost (184kW/250PS) - MI4.

NOTE: No sudden impact force is allowed.
• Press the fuel rail down into the cylinder head injector bores by hand, then install and hand start fuel rail bolts 3 and 4.

• Release the force before tightening.

• Install the remaining fuel rail bolts. Tighten all of the fuel rail bolts in the sequence shown in illustration and in the following 5 stages.

  Torque:

  Stage 1: 89 lb.in (10 Nm)

  Stage 2: Release the torque to : 0 lb.in (0 Nm)

  Stage 3: Wait 5s

  Stage 4: 124 lb.in (14 Nm)

  Stage 5: 30°

• Connect the fuel injector electrical connectors and then install the fuel rail insulator.

• Connect the FRP sensor electrical connector.

Install the new high-pressure fuel tube and tighten the high pressure fuel tube flare nuts only finger tight at this stage.

Tighten the high pressure fuel tube flare nuts in the following 3 stages.

Torque:

Stage 1: 62 lb.in (7 Nm)

Stage 2: 133 lb.in (15 Nm)

Stage 3: 30°

• 1.
  
  Tighten the high-pressure fuel tube nut.

  Torque: 89 lb.in (10 Nm)

• 2.
  
  Tighten the high-pressure fuel tube bolt.

  Torque: 89 lb.in (10 Nm)

Torque: 97 lb.in (11 Nm)

Install the high-pressure fuel pump noise insulator.