Direct Injection Fuel Rail LH: Installation

1. Install the Teflon® Seal Guide onto 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® seals onto the Teflon® Seal Guide, using the Pusher Tool, slide the Teflon® seals along the Teflon® Seal Guide.

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.
4. Remove the special tools.

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1. Use a soft brush to clean the inside of the re-forming tool before each use.
2. 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.
3. 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.
4. 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.
5. After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.

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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 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 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 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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Install the fuel injectors to the fuel rail.

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Install the fuel rail, push down on the fuel rail above the fuel injectors, apply an even force to ensure that the fuel rail seats parallel to the cylinder head mounting bosses. Install the bolts and hand tighten until snug.

Torque: Stage 1: Tighten the bolts one revolution at the time, in the sequence shown, until all of the fuel rail mounting brackets are seated flat on the cylinder head mounting bosses: : 1 turn(s) Stage 2: Tighten in the sequence shown to: : 18 lb.ft (24 Nm)

Fig 1: Fuel Rail Bolts Tightening Sequence

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1. Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas below.

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2. NOTE: In stage 2, if the torque required to tighten any flare nut on the new high-pressure fuel tube reaches or exceeds 55 lb.ft (75 Nm), then that high pressure fuel tube must be discarded and replaced with another new high-pressure fuel tube.

   Install the high-pressure fuel tube and tighten the flare nuts finger tight, then tighten the flare nuts in the following 2 stages.

   Torque: Stage 1: Tighten to : 62 lb.in (7 Nm) Stage 2: Tighten an additional : 30 deg.

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