Fuel Rail: Installation

NOTE: Note the correct orientation of the fuel injector support rings for correct installation of the new fuel injector support rings.

Remove and discard the fuel injector O-rings. Remove and discard the fuel injector support rings.

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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.
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NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
1. Install the Arbor onto 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 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.
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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 the Teflon® seal sizer tool.
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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.

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.
1. Install the new the fuel injector support rings.
2. Install the new fuel injector O-rings and lubricate with clean engine oil.
  Material: Motorcraft® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
3. Install the new the fuel injector clips.
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NOTE: The FRP sensor must be replaced if it is removed from the fuel rail.

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

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

NOTE: Only tighten the 4 fuel rail bolts finger tight at this stage.

Install the fuel rail, push down on the fuel rail above the fuel injectors. Install and tighten the fuel rail bolts in the following 2 stages and in the sequence shown.

Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 17 lb.ft (23 Nm)

Fig 1: Fuel Rail Tightening Sequence
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Connect the fuel injector electrical connectors.

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

Make sure that a new high pressure fuel tube is installed.

Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas in the chart below. Install the new high-pressure fuel tube, then tighten the high-pressure fuel tube flare nuts in the following 3 stages.

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Torque: Stage 1: 15 lb.ft (21 Nm) Stage 2: Wait 5min Stage 3: 15 lb.ft (21 Nm)

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Install the ignition coil-on-plug mounting bracket insulator.

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1. Install the ignition coil-on-plug mounting bracket, then install and tighten the ignition coil-on-plug mounting bracket retainers.
  Torque: 89 lb.in (10 Nm)
2. Install and tighten the ignition coil-on-plug mounting bracket retainers.
  Torque: 53 lb.in (6 Nm)
- Install the wiring harness, then attach the wiring harness retainers. Connect the FRP sensor electrical connector, the fuel injection pump electrical connector and the CMP electrical connector.
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NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.

Install the high-pressure fuel pump noise insulator.

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1. Install the TC inlet pipe.
2. Install and tighten the TC inlet pipe ball stud and retaining nut.
  Torque: 44 lb.in (5 Nm)
3. Tighten the TC inlet tube clamp.
  Torque: 44 lb.in (5 Nm)
4. Install the crankcase ventilation tube and clamp.
5. Connect the crankcase ventilation tube quick release coupling. Refer to: Quick Release Coupling .
6. Attach the hose retainer.
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Install the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
Install the ignition coil-on-plug. Refer to: Ignition Coil-On-Plug .
Connect the battery. Refer to: Battery Disconnect and Connect .
Pressurize the fuel system. Refer to: Fuel System Pressure Release .