Fuel Rail: Installation

Remove and discard the fuel injector O-rings. Remove and discard the fuel injector support rings.

• 1.
  
  Pull the lower Teflon ® seal away from the injector with narrow tip pliers.

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

• 1.
  
  Install the Arbor (part of the Fuel Injector Seal Installer) on the fuel injector tips. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.

• 2.
  
  
  NOTE: Once the Teflon ® seal is installed on the Arbor, 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.

• 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.

• 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 the Teflon ® seal sizer tool.

• 1.
  
  
  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.

  Install the new the fuel injector support rings.

• 2.
  
  
  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.

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

• 3.
  
  
  NOTE: Make sure that new fuel injector clips are installed.

  Install the new the fuel injector clips.

Install the fuel injectors to the fuel rail. Refer to: Fuel Rail Pressure (FRP) Sensor .

Install the fuel rail, push down on the fuel rail above the injectors. Install and tighten the fuel rail bolts in the sequence shown and in the following 2 stages.

Torque:

Stage 1: 71 lb.in (8 Nm)

Stage 2: 26 °

• Install the fuel rail insulator.

• Attach the wiring harness retainers.

• Attach the fuel rail electrical connector.

• 1.
  
  
  NOTE: Make sure that a new high-pressure fuel tube is installed.

  Install the new high-pressure fuel tube, then install the high-pressure fuel tube flare nuts, the high-pressure fuel tube bracket bolt and the high-pressure fuel tube bracket nut finger tight at this stage.

• 2.
  
  
  NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas in the chart below.

  Tighten the high-pressure fuel tube flare nuts in the following 3 stages.

  Torque:

  Stage 1: 62 lb.in (7 Nm)

  Stage 2: 133 lb.in (15 Nm)

  Stage 3: 30 °

• 3.
  
  Tighten the high-pressure fuel tube bracket nut.

  Torque: 150 lb.in (17 Nm)

• 4.
  
  Tighten the high-pressure fuel tube bracket bolt.

  Torque: 89 lb.in (10 Nm)

Install the high-pressure fuel pump noise insulator.