Fuel Rail: Installation

Both fuel rails 

1. NOTE: Do not lubricate the new lower Teflon ® fuel injector seal.
   1. Install the Arbor on 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 ® seal onto the Arbor, using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon ® seal along the Arbor.

   3. Using the Pusher Tool, slide the Teflon ® seal off of the Teflon ® Seal Guide and into the groove on the fuel injector. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.

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2. 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.
   4. After one minute, turn the Teflon ® seal sizer tool back 180 degrees and remove.

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3. NOTE: Make sure that new fuel injector support rings and new fuel injector O-ring seals are installed.
   1. 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 old O-ring seals.
      NOTE: Do not lubricate the new lower Teflon ® fuel injector seals.

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

   2. 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.

   3. Inspect the inlet stopper, if it is damaged or comes off discard the inlet stopper. The inlet stopper is not needed for proper function. Ensure that any debris from the inlet stopper are removed. If the inlet stopper is intact and undamaged do not remove the inlet stopper from the fuel injector.
   4. The upper side of the support ring has the wide surface area.
   5. Fuel injector support ring.
   6. The lower side of the support ring has the narrow surface area.

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4. NOTE: Make sure that new fuel injector clips are installed.

   Install the new the fuel injector clips.

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   Right fuel rail 

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

   Install the fuel injectors to the fuel rail.

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6. Connect the fuel injector electrical connectors.

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

   Install the fuel rail, push down on the fuel rail above the injectors, then install and tighten the fuel rail bolts.

   Torque: 18 lb.ft (24 Nm)

   Fig 1: Fuel Rail Tightening Sequence

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8. Attach the wiring harness retainer.

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9. NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas in the chart below.
   NOTE: Make sure that a new high-pressure fuel pump-to-fuel rail high-pressure fuel tube is installed.

   Install the high-pressure fuel pump-to-fuel rail high-pressure fuel tube and tighten the flare nuts finger tight, then tighten the flare nuts in the following 3 stages.

   Torque:

   Stage 1: 62 lb.in (7 Nm)

   Stage 2: 89 lb.in (10 Nm)

   Stage 3: 25 °

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   Left fuel rail 

10. NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.
    • Install the fuel injectors to the fuel rail.
    • NOTE: The FRP sensor must be replaced if it is removed from the fuel rail.

      Refer to: Fuel Rail Pressure (FRP) Sensor .

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11. Connect the fuel injector electrical connectors.

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

    Install the fuel rail, push down on the fuel rail above the injectors, then install and tighten the fuel rail bolts.

    Torque: 18 lb.ft (24 Nm)

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13. Attach the wiring harness retainer.

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    Both fuel rails 

14. NOTE: Make sure that a new fuel rail-to-fuel rail high-pressure fuel tube is installed.
    NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas in the chart below.

    Install the fuel rail-to-fuel rail high-pressure fuel tube and tighten the flare nuts finger tight, then tighten the flare nuts in the following 3 stages.

    Torque:

    Stage 1: 62 lb.in (7 Nm)

    Stage 2: 89 lb.in (10 Nm)

    Stage 3: 25 °

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15. 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.

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16. Install the intake manifold. Refer to: Intake Manifold .
17. Connect the battery. Refer to: Battery Disconnect and Connect .
18. Pressurize the fuel system. Refer to: Fuel System Pressure Release .