Fuel Rail: Installation

NOTE: A clean working environment is essential to prevent dirt or foreign material contamination.

1.
- 1.
  
  Remove and discard the fuel injector O-rings.
- 2.
  
  NOTE: Note the correct orientation of the fuel injector support rings for correct installation of the fuel injector support rings.
  
  Remove and discard 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 necessary 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.

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2.

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, remove and discard the lower fuel injector Teflon® seals.

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3.

NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
- 1.
  
  Install the Arbor on the fuel injector tips. Special Tool(s): Seal Installer, Fuel Injector 310-207.
- 2.
  
  NOTE: Make sure that new lower fuel injector Teflon® seals are installed.
  
  NOTE: Once the Teflon® seal is installed on the Teflon® Seal Guide 310-207 (part of the Fuel Injector Seal Installer), it should immediately be installed onto the fuel injector to avoid excessive expansion of the Teflon® seal.
  
  Install the new Teflon® seals onto the Arbor, using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon® seals along the Arbor. Special Tool(s): 310-207.
- 3.
  
  Using the Pusher Tool 310-207 (part of the Fuel Injector Seal Installer), slide the Teflon® seals off of the Teflon® Seal Guide and into the groove on the fuel injectors. Special Tool(s): Seal Installer, Fuel Injector 310-207.

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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.

4.
- 1.
  
  NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.
  
  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 303-1567 with the larger opening towards the Teflon® seal. Push while turning the Teflon® seal sizer tool 180 degrees. Special Tool(s): Sizer, Teflon® Seal 303-1567.
- 3.
  
  Once the Teflon® seal sizer tool 303-1567 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: Make sure that new upper fuel injector O-ring seals, upper fuel injector O-ring seal support rings and fuel injector retainer clips are installed.

5.
- 1.
  
  NOTE: The new the fuel injector support rings must be installed in the correct orientation with the larger diameter 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.
  
  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.
  
  Install the new fuel injector O-rings and lubricate with clean engine oil. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-30 Super Premium Motor Oil (Canada) XO-5W30-QSP (US); CXO-5W30-LSP12 (Canada); or equivalent.
- 3.
  
  Inspect the inlet stopper, if it is damaged or comes off discard the inlet stopper. The inlet stopper is not necessary 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.

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

6.
Install the new the fuel injector clips.

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

NOTE: The FRP sensor must be replaced if it is removed from the fuel rail. Refer to Electronic Engine Controls .

7.
Install the fuel injectors to the fuel rail.

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8.

Connect the fuel injector electrical connectors.

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9.

NOTE: Tighten the bolts in a method that draws the fuel rail evenly to the head, preventing a rocking motion.

NOTE: Make sure that new fuel rail bolts are installed.

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

Tighten the new fuel rail bolts in the following 3 stages.
- Stage 1: Push down on the fuel rail face above the injectors.
- Stage 1: Tighten to 10 Nm (89 lb-in) in the sequence shown in illustration.
- Stage 2: Tighten an additional 45 degrees in the sequence shown.

Fig 1: Fuel Rail Tightening Sequence

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10.

Attach the fuel injector wire harness electrical connector retainers and the fuel injector wire harness retainer to the fuel rail.

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11.

Connect the fuel injector wire harness connectors and the fuel rail pressure sensor wire connector.

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12.

Attach the fuel injector wire harness retainers to the fuel rail.

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13.

NOTE: Make sure that a new high pressure fuel tube, a new high pressure fuel tube bracket nut and a new high pressure fuel tube bracket bolt are installed.

NOTE: Install the new high pressure fuel tube, the high pressure fuel tube flare nuts, the new high pressure fuel tube bracket nut, the new bracket bolt and tighten finger tight at this stage. Tighten in the sequence shown in illustration.

NOTE: Calculate the correct torque wrench setting for the following torque in illustration.
- 1.
  
  Tighten the high pressure fuel tube-to-RH fuel rail tube flare nut.
  - Stage 1: Tighten to 15 Nm (133 lb-in).
  - Stage 2: Tighten an additional 45 degrees or 50 Nm (37 lb-ft), whichever comes first.
- 2.
  
  Tighten the high pressure fuel tube-to-LH fuel rail tube flare nut.
  - Stage 1: Tighten to 15 Nm (133 lb-in).
  - Stage 2: Tighten an additional 45 degrees or 50 Nm (37 lb-ft), whichever comes first.
- 3.
  
  Tighten the high pressure fuel tube-to-high-pressure fuel pump flare nut.
  - Stage 1: Tighten to 15 Nm (133 lb-in).
  - Stage 2: Tighten an additional 45 degrees or 50 Nm (37 lb-ft), whichever comes first.
- 4.
  
  Tighten the high pressure fuel tube bracket bolt.
  - Stage 1: Tighten to 10 Nm (89 lb-in).
  - Stage 2: Tighten an additional 45 degrees.
- 5.
  
  Tighten the high pressure fuel tube bracket nut.
  - Tighten to 8 Nm (71 lb-in).

Fig 2: Torque Wrench Adapter Formulas

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Fig 3: High Pressure Fuel Tube Tightening Sequence

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NOTE: Lubricate the new coolant inlet pipe O-ring seals with clean engine coolant prior to installation.

14.
Install the new coolant inlet pipe O-ring seals and lubricate the new coolant inlet pipe O-ring seals with clean engine coolant. Material: Motorcraft® Orange Antifreeze/Coolant Concentrated VC-3-B (US); CVC-3-B2 (Canada) WSS-M97B44-D.

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15.

Install the coolant inlet pipe.

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16.

Install the new coolant crossover assembly gaskets.

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17.

Install the coolant crossover assembly bolts and the coolant crossover assembly. Tighten the coolant crossover assembly bolts to 10 Nm (89 lb-in).

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18.

Install the intake manifold, refer to INTAKE MANIFOLD .

19.

Connect the battery ground cable, refer to Battery, Mounting and Cables .

20.

Pressurize the fuel system, refer to Fuel System - General Information .

21.

Fill and bleed the cooling system, refer to Engine Cooling .

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

22.
Install the fuel injection pump noise insulator.

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23.

Remove the oil filler cap and install the engine appearance cover. Install the oil filler cap.

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