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Home >> Ford >> 2020 >> Fusion Titanium, AWD >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Fuel Charging And Controls - 2.0L ECOBOOST (184KW/250PS) - Mi4 >> Removal And Installation >> Fuel Rail >> Installation

Fuel Rail: Installation

  1. 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.

    GFD481449Courtesy of FORD MOTOR COMPANY
  2. 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.

    GFD481450Courtesy of FORD MOTOR COMPANY
  3. 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 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: Do not lubricate the new lower Teflon® fuel injector seals.

      Install the new fuel injector O-ring seals.

    3. Install the new the fuel injector clips.

    GFD481789Courtesy of FORD MOTOR COMPANY
  4. NOTE: The FRP sensor must be replaced if it is removed from the fuel rail.
    NOTE: The anti-rotation finger of the fuel injector must slip into the groove of the fuel rail cup.

    Install the fuel injectors to the fuel rail.

    GFD481790Courtesy of FORD MOTOR COMPANY
  5. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

    • NOTE: No sudden impact force is allowed.
      NOTE: Make sure that new bolts are installed.

      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 and in the following 5 stages.

      Torque: Stage 1: Tighten to: : 89 lb.in (10 Nm) - Stage 2: Release the torque to: : 0 lb.in (0 Nm) - Stage 3: Wait 5s - Stage 4: Tighten to: : 124 lb.in (14 Nm) - Stage 5: Tighten an additional: : 30°

    Fig 1: Fuel Rail Tightening Sequence
    GFD481791Courtesy of FORD MOTOR COMPANY
    • Connect the fuel injector electrical connectors and then install the fuel rail insulator.

    • Connect the FRP sensor electrical connector.

    GFD481782Courtesy of FORD MOTOR COMPANY
  7. Connect the electrical connector retainer to the fuel rail tab.
    GFD481781Courtesy of FORD MOTOR COMPANY
  8. NOTE: Make sure that a new high-pressure fuel tube is installed.

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

    GFD481792Courtesy of FORD MOTOR COMPANY
  9. Install the high-pressure fuel tube nut and bolt only tighten finger tight at this stage.
    GFD481779Courtesy of FORD MOTOR COMPANY
  10. NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas in the chart below.
    G00468730Courtesy of FORD MOTOR COMPANY

    Tighten the high pressure fuel tube flare nuts in the following 2 stages.

    Torque: Stage 1: 133 lb.in (15 Nm) - Stage 2: 30°

    GFD481793Courtesy of FORD MOTOR COMPANY
    1. Tighten the high-pressure fuel tube nut.

      Torque: 150 lb.in (17 Nm)

    2. Tighten the high-pressure fuel tube bolt.

      Torque: 89 lb.in (10 Nm)

    GFD481779Courtesy of FORD MOTOR COMPANY
  12. Install the evaporative emission canister purge valve, then install and tighten the evaporative emission canister purge valve bracket nuts.

    Torque: 97 lb.in (11 Nm)

    GFD481778Courtesy of FORD MOTOR COMPANY
  13. NOTE: When removing or installing the high-pressure fuel pump noise insulator, spreading the openings will reduce the risk of damage.

    Install the high-pressure fuel pump noise insulator.

    GFD481794Courtesy of FORD MOTOR COMPANY
  14. Connect the high-pressure fuel pump electrical connector.
    GFD481776Courtesy of FORD MOTOR COMPANY
  15. Attach the brake vacuum line retainer.
    GFD481775Courtesy of FORD MOTOR COMPANY
  16. Install the upper air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
  17. Install the intake manifold. Refer to: Intake Manifold .
  18. Connect the battery. Refer to: Battery Disconnect and Connect .
  19. Pressurize the fuel system. Refer to: Fuel System Pressure Release .
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