Fuel Rail: Installation

NOTE: A clean working environment is essential to prevent dirt or foreign material contamination.

NOTE: Discard the upper fuel injector O-ring seals and the upper fuel injector O-ring seal support rings.

Fig 1: Locating Upper Fuel Injector O-Ring Seals And Support Rings

Courtesy of FORD MOTOR CO.

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: Be very careful when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.

Fig 2: Locating Lower Teflon® Seal

Courtesy of FORD MOTOR CO.

Pull the lower Teflon® seal away from the injector with narrow tip pliers.
Carefully cut and discard the lower fuel injector Teflon® seals.

Fig 3: Cutting Lower Fuel Injector Teflon® Seal
Courtesy of FORD MOTOR CO.
Place the Teflon® Seal Sizer, knurled side out, over the fuel injector tip until the fuel injector seal recess is exposed.
1. 303-1567.
2. 310-207.
4. 310-207.
  
  Fig 4: Installing Teflon® Seal Using Special Tools
  Courtesy of FORD MOTOR CO.
Install fuel injectors.
NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the seal.

NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion.
1. 303-1567.
  
  Fig 5: Installing Fuel Injector Into Cylinder Head
  Courtesy of FORD MOTOR CO.

NOTE: Use 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: Lubricate the upper fuel injector O-ring seals with clean engine oil.

NOTE: Make sure that new upper fuel injector O-ring seals, upper fuel injector O-ring seal support rings and fuel injector retainer clips are installed.

Fig 6: Installing Fuel Injector Retainer Clips

Courtesy of FORD MOTOR CO.

Install fuel injector retainer clips.
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. For additional information, refer to ELECTRONIC ENGINE CONTROLS .

Fig 7: Locating Fuel Rail Pressure Sensors
Courtesy of FORD MOTOR CO.

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

NOTE: Make sure that new fuel rail bolts are installed.

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.
  
  Fig 8: Fuel Rail Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install fuel injector electrical connectors.

Fig 9: Locating Electrical Connector
Courtesy of FORD MOTOR CO.

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

- Hand tighten the high pressure fuel tube-to-fuel rail flare nut.
- Hand tighten the high pressure fuel tube-to-fuel injection pump flare nut.
  
  Fig 10: Locating High Pressure Fuel Tube-To-Fuel Rail And High Pressure Fuel Tube-To-Fuel Injection Pump Flare Nuts
  Courtesy of FORD MOTOR CO.
Loosely install the 2 high pressure fuel tube bracket bolts.

Fig 11: Locating High Pressure Fuel Tube Bracket Bolts
Courtesy of FORD MOTOR CO.
Tighten the 2 high pressure fuel tube flare nuts in the following 2 stages.
NOTE: Calculate the correct torque wrench setting for the following torque. Refer to Fig 12 .

Fig 12: Torque Wrench Adapter Formulas
Courtesy of FORD MOTOR CO.
- Stage 1: Using a torque adapter, tighten to 15 Nm (133 lb-in).
- Stage 2: Tighten an additional 30 degrees.
  
  Fig 13: Locating High Pressure Fuel Tube Flare Nuts
  Courtesy of FORD MOTOR CO.
Tighten to 10 Nm (89 lb-in).

Fig 14: Locating Fuel Injection Pump Nuts
Courtesy of FORD MOTOR CO.

NOTE: Use care when installing the fuel injection pump noise insulator. Spreading the openings will aid in installing the fuel injection pump noise insulator and reduce the risk of damage.

Fig 15: Remove/Install Fuel Injector Electrical Connector

Courtesy of FORD MOTOR CO.

Install the intake manifold. For additional information, refer to ENGINE - 2.0L GTDI .
Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Pressurize the fuel system, For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .