Direct Injection Fuel Rail: Installation

NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
1. Install the Teflon® Seal Guide onto the fuel injector tip. 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 Teflon® Seal Guide, using the Pusher Tool, slide the Teflon® seals along the Teflon® Seal Guide.
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.
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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. NOTE: The beveled opening of the Teflon® seal sizer tool goes away from the seal.
  
  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.
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NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
- Install the new fuel injector support rings as noted during removal.
- Install the new fuel injector O-ring seals and lubricate them with clean engine oil.
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Install the fuel injector clips.

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NOTE: The fuel injector clip must lock into the slot of the fuel rail cup.

Install the fuel injectors to the fuel rail, then connect the fuel injector electrical connectors.

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

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

Install the fuel rail, push down on the fuel rail above the injectors. Install and tighten the fuel rail bolts in the following 3 stages and in the sequence shown.

Torque:

Stage 1: Tighten to: : 44 lb.in (5 Nm) | Stage 2: Loosen: : 90 deg.Stage 3: Tighten to: : 24 lb.ft (33 Nm)

Fig 1: Fuel Rail Bolts Tightening Sequence
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NOTE: Make sure that a new high pressure fuel tube is installed.

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

Install the new high-pressure fuel tube, then tighten the high-pressure fuel tube flare nuts in the following 3 stages.

Torque

:Stage 1: Tighten to: : 124 lb.in (14 Nm) | Stage 2: Tighten to: : 177 lb.in (20 Nm) | Stage 3: Tighten an additional: : 20 deg.

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

Install the noise insulator.

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Install the hose and connect the quick release couplings. Refer to: Quick Release Coupling .

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Install the hose and connect the quick release couplings. Refer to: Quick Release Coupling .

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Connect the electrical connectors, then attach the wiring harness retainers.

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Connect the fuel supply tube spring lock coupling. Refer to: Spring Lock Couplings .

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Install the ignition coil-on-plugs. 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 .