Direct Injection Fuel Rail LH: Installation

NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
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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NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.

NOTE: The beveled opening of the Teflon® seal sizer tool goes away from the seal.

NOTE: Do not use the injector without re-forming the Teflon seal after replacing.
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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NOTE: Make sure that new fuel injector support rings and new fuel injector O-ring seals are installed.
1. 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.
2. Install the new fuel injector O-ring seals.
3. Install the new the fuel injector clips.
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NOTE: Do not re-use a fuel injector if it is dropped.

Install the fuel injectors to the fuel rail.

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Connect the fuel injector electrical connectors.

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

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

Torque: Stage 1: Tighten to : 10 Nm Stage 2: Tighten an additional : 45°

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

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

Install the high-pressure fuel tube and tighten the flare nuts finger tight.
NOTE: In stage 3, 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.

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

Torque: Stage 1: Tighten to : 9 Nm Stage 2: Tighten to : 10 Nm Stage 3: Tighten an additional : 38°

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Connect the fuel injector main harness electrical connector.

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Install the direct injection fuel rail RH. Refer to: Direct Injection Fuel Rail RH .