E 450 V8-5.4L (2009)
Fuel Rail: Service and Repair
Fuel Rail
Fuel Rail - 5.4L
Removal and Installation
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component.
Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent
accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this
instruction may result in serious personal injury.
NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute
cleanliness is observed when working with these components. Always install plugs to any open orifices or tubes. Failure to follow these
instructions may result in fuel injection component damage.
NOTICE: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector
retaining clip area before separating from the tube. Failure to follow these instructions may result in fuel or vapor leaks and connector damage.
1. Disconnect the battery ground cable.
2. Remove the engine cover.
3. Relieve the fuel pressure.
4. Remove the Air Cleaner (ACL) and the ACL outlet tube.
5. Disconnect the fuel supply tube quick connect coupling.
6. Disconnect the quick connect couplings and remove the PCV tube.
7. Disconnect the 8 fuel injector electrical connectors.
8. Remove the 4 fuel rail bolts.
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To install, tighten to 10 Nm (89 lb-in).
9. NOTE: When removing the fuel rail, leave the fuel injectors in the intake manifold. This will make removal of the fuel rail easier.
Separate the fuel rail from the 8 fuel injectors and remove the fuel rail.
10. NOTE: Install new fuel injector-to-fuel rail O-ring seals on the fuel injectors.
NOTE: Lubricate the new fuel injector-to-fuel rail O-ring seals with clean engine oil prior to installation.
Remove the 8 fuel injectors from the intake manifold.
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Remove and discard the fuel injector O-ring seals.
