Fuel Rail: Installation

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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. 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.
  
  Make sure that new lower fuel injector Teflon® seals are installed.
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: 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. Some Teflon ® seal massaging with your fingers before the Teflon ® seal sizer tool is installed 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. After one minute, turn the Teflon ® seal sizer tool back 180 degrees and remove.
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NOTE: The large diameter step of the backup ring must go up towards the new O-ring seal. Improperly installed backup rings may cause the fuel system to leak.

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.

Material: Motorcraft ® SAE 5W-30 Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

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

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

Refer to: Fuel Rail Pressure (FRP) Sensor

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

Push down on the fuel rail above the injectors. Tighten in the sequence shown:

Torque:

Stage 1: 71 lb.in (8 Nm)

Stage 2: 26 °

Fig 1: Fuel Rail Tightening Sequence
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NOTE: Only tighten the 2 high pressure fuel tube flare nuts finger tight at this stage.

NOTE: Only tighten the high pressure fuel tube bracket bolt and nut finger tight at this stage.
1. NOTE: Make sure that a new high pressure fuel tube is installed.
2. NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas in the chart below.
  
  Torque:
  
  :Stage 1: 62 lb.in (7 Nm)
  
  Stage 2: 133 lb.in (15 Nm)
  
  Stage 3: 30 °
3. Torque: 89 lb.in (10 Nm)
4. Torque: 150 lb.in (17 Nm)
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NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.

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Install the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe
Install the intake manifold. Refer to: Intake Manifold
Reconnect the battery. Refer to: Battery Disconnect and Connect
Pressurize the fuel system. Refer to: Fuel System Pressure Release

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