Fuel Rail: Installation

• 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.

• 1.
  
  Pull the lower Teflon ® seal away from the injector.

• 2.
  
  Carefully cut, remove and discard the lower fuel injector Teflon ® seals.

• 1.
  
  Install the Arbor on the fuel injector tips. Special Tool(s): Seal Installer, Fuel Injector 310-207.

• 2.
  
  
  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.
  NOTE: Make sure that new lower fuel injector Teflon ® seals are installed.

  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.

• 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.

• 1.
  
  Install the new fuel injector O-rings. The O-rings are pre-lubricated, NO ADDITIONAL lubricant is required.

• 2.
  
  
  NOTE: The new the fuel injector support rings must be installed in the correct orientation with the wider surface 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 then 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 wider surface area.

• 5.
  
  Fuel injector support ring.

• 6.
  
  The lower side of the support ring has the narrow surface area.

Install the new the fuel injector clips.

Install the fuel injectors to the fuel rail.

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.

• Stage 2: Tighten an additional 45 degrees in the sequence shown.

NOTE: Calculate the correct torque wrench setting for the following torque. Refer to the Torque Wrench Adapter Formulas in the chart below.

• 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).

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.

Install the fuel injection pump noise insulator.