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Home >> Ford >> 2018 >> Mustang EcoBoost, 2D Convertible, Automatic Trans >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls - Fuel Charging And Controls - 2.3L ECOBOOST (231KW/314PS) >> Removal And Installation >> Fuel Rail >> Installation
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Fuel Rail: Installation

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

    GFD286921Courtesy of FORD MOTOR COMPANY
  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 with narrow tip pliers.
    2. Carefully cut, remove and discard the lower fuel injector Teflon® seals.

    GFD286922Courtesy of FORD MOTOR COMPANY
  3. NOTE: Do not lubricate the new lower Teflon® fuel injector 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.

    GFD286923Courtesy of FORD MOTOR COMPANY
  4. 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 the Teflon® seal sizer tool.

    GFD286924Courtesy of FORD MOTOR COMPANY
  5. NOTE: Make sure that new fuel injector support rings and new fuel injector O-ring seals are installed.

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

      Install the new fuel injector O-rings.

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

      Install the new the fuel injector clips.

    GFD286925Courtesy of FORD MOTOR COMPANY
  6. 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.

    Install the fuel injectors to the fuel rail.

    GFD286926Courtesy of FORD MOTOR COMPANY
  7. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

    • NOTE: No sudden impact force is allowed.
      NOTE: Make sure that new bolts are installed.

      Press the fuel rail down into the cylinder head injector bores by hand, then install and hand start fuel rail bolts 3 and 4.

    • Release the force before tightening.

    • Install the remaining fuel rail bolts. Tighten all of the fuel rail bolts in the sequence shown and in the following 5 stages.

      Torque: Stage 1: Tighten to: 89 lb.in (10 Nm) Stage 2: Release the torque to: 0 lb.in (0 Nm) Stage 3: Wait 5s Stage 4: Tighten to: 124 lb.in (14 Nm) Stage 5: Tighten an additional: 30°

    Fig 1: Fuel Rail Tightening Sequence
    GFD286927Courtesy of FORD MOTOR COMPANY
  8. Connect the fuel injector and the FRP sensor electrical connectors.
    GFD286915Courtesy of FORD MOTOR COMPANY
    • Install the fuel rail insulator.

    • Attach the wiring harness retainers.

    • Attach the fuel rail electrical connector.

    GFD286914Courtesy of FORD MOTOR COMPANY
    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.
      G00468730Courtesy of FORD MOTOR COMPANY

      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)

    GFD286899Courtesy of FORD MOTOR COMPANY
  11. Install the high-pressure fuel pump drive unit noise insulator and install the brake vacuum pump noise insulator. Install the high-pressure fuel pump drive unit noise insulator retainer, install the brake vacuum pump noise insulator retainer and install the wire harness retainer.
    GFD286887Courtesy of FORD MOTOR COMPANY
  12. Connect the HO2S electrical connector retainer to the high-pressure fuel pump bracket.
    GFD286886Courtesy of FORD MOTOR COMPANY
  13. 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.

    GFD286884Courtesy of FORD MOTOR COMPANY
  14. Connect the high-pressure fuel pump electrical connector.
    GFD286883Courtesy of FORD MOTOR COMPANY
  15. Install the intake manifold. Refer to: Intake Manifold .
  16. Reconnect the battery. Refer to: Battery Disconnect and Connect .
  17. Pressurize the fuel system. Refer to: Fuel System Pressure Release .
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