Direct Injection Fuel Rail LH: Installation

1. Remove and discard the fuel injector O-ring seals.
2. NOTE: Note the correct orientation of the fuel injector support rings for correct installation of the NEW fuel injector support rings.
  
  Remove and discard 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.
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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. NOTE: The beveled opening of the Teflon® seal sizer tool goes away from the seal.
  
  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. 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 NEW 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.

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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 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: Cylinder Head Mounting Bosses Hand Tightening Sequence
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Connect the fuel injector harness retainer.

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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.

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 NEW 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.

Torque: Stage 1: 62 lb.in (7 Nm) | Stage 2: 89 lb.in (10 Nm) | Stage 3: Tighten an additional : 25°

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Install the intake manifold. Refer to: Intake Manifold .
Install the cowl panel. Refer to: Cowl Panel .
Connect the battery negative cable. Refer to: Battery Disconnect and Connect .
Pressurize the fuel system. Refer to: Fuel System Pressure Release .