Direct Injection Fuel Rail RH: Installation

NOTE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injector.

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.
2. Carefully cut and discard the lower fuel injector Teflon® seal.
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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.
1. 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.
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.
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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. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
  
  Install the new fuel injector O-ring seals.
3. Install the new the fuel injector clips.
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NOTE: The anti-rotation finger of the fuel injector must slip into the groove of the fuel rail cup.

Install the fuel injectors to the fuel rail, then 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 and in the sequence shown below.

Torque:Stage 1: 89 lb.in (10 Nm) Stage 2: 45 deg.

Fig 1: Fuel Rail Bolts Tightening Sequence
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Connect the fuel injector main harness electrical connector.

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

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NOTE: Make sure that a new high-pressure fuel pump to fuel rail high-pressure fuel tube is installed.
1. Install the high-pressure fuel pump to fuel rail high-pressure fuel tube and tighten the flare nuts finger tight.
2. Install the high-pressure fuel pump to fuel rail high-pressure fuel tube retaining bolts finger tight.
3. Tighten the high-pressure fuel pump to fuel rail high-pressure fuel tube flare nuts in the following 3 stages.
  - Stage 1: Tighten to: 62 lb.in (7 Nm).
  - Stage 2: Tighten to: 89 lb.in (10 Nm).
  - Stage 3: Tighten an additional 30 - 45 degrees and record the torque for each flare nut. 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.
4. Tighten the high-pressure fuel pump to fuel rail high-pressure fuel tube retaining bolts in the following 2 stages.
  Torque:Stage 1: 89 lb.in (10 Nm) Stage 2: 45 deg.
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NOTE: Make sure that a new fuel rail to fuel rail high-pressure fuel tube is installed.

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

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Install the fuel rail to fuel rail high-pressure fuel tube and tighten the flare nuts finger tight, then tighten the flare nuts in the following 3 stages.
- Stage 1: Tighten to: 62 lb.in (7 Nm).
- Stage 2: Tighten to: 89 lb.in (10 Nm).
- Stage 3: Tighten an additional 30 - 45 degrees and record the torque for each flare nut. 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.
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Install the port injection fuel rail LH and RH. Refer to: Port Injection Fuel Rail LH . Refer to: Port Injection Fuel Rail RH .