Fuel Rail - 3.5L GTDI: Installation

Using the Fuel Injector Brush, clean the fuel injector bore in the cylinder head. Special Tool(s): 310-205.

• 1.
  
  Pull the lower Teflon® seal away from the fuel injector.

• 2.
  
  Carefully cut and discard the lower fuel injector Teflon® seal.

• 1.
  
  
  NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

  Install the Arbor on the fuel injector tip. Special Tool(s): 310-207.

• 2.
  
  
  NOTE: Once the Teflon® seal is installed on the Teflon® Seal Guide 310-207 (part of the Fuel Injector Seal Installer), 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® seal onto the Arbor, using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon® seal along the Arbor. Special Tool(s): 310-207.

• 3.
  
  Using the Pusher Tool, slide the Teflon® seal off of the Teflon® Seal Guide and into the groove on the fuel injector. Special Tool(s): 310-207.

• 1.
  
  
  NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.

  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. Special Tool(s): 303-1567.

• 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.

• 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: 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.

  1. Install the new the fuel injector support rings.

• 2. Install the new fuel injector O-ring seals and lubricate them with clean engine oil. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-30 Super Premium Motor Oil (Canada) XO-5W30-QSP (US); CXO-5W30-LSP12 (Canada); or equivalent.

• 3. Install the new the fuel injector clips.

Install the fuel injectors to the fuel rail.

Install the fuel charge wire harnesses, connect the Fuel Rail Pressure (FRP) sensor and the fuel injector electrical connectors. Install the tie straps to the index-marked locations on the fuel rails. Start by attaching the first tie strap farthest down the wire harness and continue to the connector end of the harness, leaving ample slack between the fuel injectors.

Install the fuel rail and the new fuel rail bolts. Tighten the fuel rail bolts in the following 3 stages.

• Stage 1: Push down on the fuel rail face above the injectors.

• Stage 1: Tighten to 10 Nm (89 lb-in) in the sequence shown in illustration.

• Stage 2: Tighten an additional 45 degrees in the sequence shown in illustration.

Install the fuel rail and the new fuel rail bolts. Tighten the fuel rail bolts in the following 3 stages.

• Stage 1: Push down on the fuel rail face above the injectors.

• Stage 1: Tighten to 10 Nm (89 lb-in) in the sequence shown in illustration.

• Stage 2: Tighten an additional 45 degrees in the sequence shown in illustration.

• 1.
  
  
  NOTE: Calculate the correct torque wrench setting for the following torque. Refer to the Torque Wrench Adapter Formulas in Fig 1

  Install the high-pressure fuel tube and tighten the flare nuts in the following 3 stages.

  • Stage 1: Tighten to 32 Nm (24 lb-ft).
  • Stage 2: Wait 10 minutes to minimize pre-stress.
  • Stage 3: Tighten to 32 Nm (24 lb-ft).

• 2.
  
  
  • Tighten to 8 Nm (71 lb-in).

Install the fuel injection pump noise insulator.