Fuel Rail: Installation
NOTE:
A clean working environment is essential to prevent dirt or foreign material contamination.
- 2.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.NOTE: Use care when removing the lower Teflon ® seals, not to scratch, nick or gouge the fuel injectors.
- 1.
Pull the lower Teflon ® seal away from the injector.
- 2.
Carefully cut and discard the lower fuel injector Teflon ® seals.
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- 3.NOTE: Do not lubricate the new lower Teflon ® fuel injector seals.
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Position the Teflon ® seal guide 310-207 (part of the Fuel Injector Seal Installer) on the tip of the fuel injector.
- 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.
- 3.
Using the Pusher Tool 310-207 (part of the Fuel Injector Seal Installer), slide the Teflon ® seals off of the Arbor and into the groove on the fuel injectors.
- 1.
- 4.NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon ® seal expansion.
- 1.NOTE: Make sure the Teflon ® seal is fully seated in the groove on the fuel injector before sizing the Teflon ® seal.
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 303-1567 with the larger opening towards the Teflon ® seal. Push while turning the Teflon ® seal sizer tool 180 degrees. Special Tool(s): 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. After one minute, turn the Teflon ® seal sizer tool back 180 degrees and remove.
- 1.
- 5.NOTE: Use new 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.NOTE: Make sure that new upper fuel injector O-ring seals, new upper fuel injector O-ring seal support rings and new fuel injector retainer clips are installed.
Material: Motorcraft ® SAE 5W-30 Premium Synthetic Blend Motor Oil (US).
- 6.NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.NOTE: The fuel rail pressure sensor must be replaced if it is removed from the fuel rail, refer to Electronic Engine Controls .
- 7.NOTE: Do not lubricate the new lower Teflon ® fuel injector seals.NOTE: Push down on the fuel rail face above the injectors.
Tighten the 5 fuel rail bolts in the following 2 stages.
- Stage 1: Tighten to 8 Nm (71 lb-in) in the sequence shown.
- Stage 2: Tighten an additional 26 degrees in the sequence shown.
- 9.NOTE: Only tighten the 2 high pressure fuel tube flare nuts finger tight at this stage.NOTE: Only tighten the 2 high pressure fuel tube bracket bolts finger tight at this stage.
- 1.NOTE: Make sure that a new high pressure fuel tube is installed.
- 2.NOTE: Calculate the correct torque wrench setting for the following torque. Refer to the Torque Wrench Adapter Formulas in the chart below.
- Stage 1: Using a torque adapter, tighten to 15 Nm (133 lb-in).
- Stage 2: Tighten an additional 30 degrees.
- 3.
Tighten to 10 Nm (89 lb-in).
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- 10.NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.
- 11.
Install the intake manifold, refer to Engine 2.0L GTDI .
- 12.
Connect the battery ground cable, refer to Battery, Mounting and Cables .
- 13.
Pressurize the fuel system, refer to Fuel System General Information .