Ford 6.4 Bomba de Alta

303-04C-i Fuel Charging and Controls — 6.
4L Diesel 303-04C-i
SECTION 303-04C Fuel Charging and Controls — 6.4L Diesel

CONTENTS PAGE
SPECIFICATIONS .................................................................................................................................................................. 303-04C-2
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-04C-2 Fuel Charging and Controls — 6.4L Diesel 303-04C-2
SPECIFICATIONS
Material
Item Specification Fill Capacity
Motorcraft® SAE 15W-40 Super Duty Diesel Motor WSS-M2C171-E —
Oil
XO-15W40-QSD (US); CXO-15W40-LSD12
(Canada)
Multi-Purpose Grease ESB-M1C93-B —
XG-4 and/or XL-5
RTV Silicone Sealant — —
TA-31
Threadlock 262 WSK-M2G351-A6 —
TA-26
General Specifications
Item Specification
High-pressure fuel injection pump gear backlash 0.13-0.33 mm (0.005-0.013 in)
Torque Specifications
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Description Nm lb-ft lb-in
Charge Air Cooler (CAC) tube clamp 8 — 71
CAC tube engine clamp 12 — 106
Crankcase vent oil separator bolts 13 — 115
Cylinder head fuel passage plug 28 21 —
Engine-to-body ground wire nut 13 — 115
Engine wiring harness bolt (at intake) 8 — 71
EGR cooler coolant tube bolt 10 — 89
EGR cooler hose clamps 4 — 35
EGR cooler inlet nuts 31 23 —
EGR cooler mounting bolts (M8) 31 23 —
EGR cooler mounting bolt (M10) 62 46 —
EGR cooler nut and bolt 31 23 —
EGR cooler retaining clip nut 12 — 106
EGR cooler stud 17 — 150
EGR-Oxidation Catalytic Converter (OC)-cylinder head bracket-to-cylinder — — —
a
head bolt
EGR-OC pipe bracket-to-cylinder head bracket bolt a — — —
EGROC-to-EGR cooler bolts

a — — —
EGR-OC-to-RH turbocharger inlet pipe bolts

a — — —
EGR-OC-to- turbocharger bracket bolts

a — — —
Exhaust downpipe-to-OC bolts

a — — —
Exhaust Pressure (EP) tube fitting 20 — 177

Front End Accessory Drive (FEAD) bracket bolts and nuts 47 35 —
Fuel cooler-to-fuel filter module return tube banjo bolts at fuel cooler 25 18 —
Fuel filter module bolts 13 — 115
Fuel filter module cover 27 20 —
Fuel filter module return tube banjo bolts (M12/copper sealing washers) 38 28 —
Fuel filter module return tube banjo bolts (M12/Viton® sealing washers) 25 18 —
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SPECIFICATIONS (Continued)
Torque Specifications (Continued)

Fuel filter module stud bolt 13 — 115
Fuel filter module supply tube banjo bolt (M14/copper sealing washer) 47 35 —
Fuel filter module supply tube banjo bolt (M14/Viton® sealing washers) 28 21 —
Fuel injection pump supply tube bracket nuts 11 — 97
Fuel injection pump high pressure fittings 45 33 —
Fuel injection pump low pressure fittings 48 35 —
Fuel injection pump supply tube nut 38 28 —
Fuel injection pump-to-fuel cooler return tube nut 38 28 —
Fuel injector hold-down clamp bolt

a — — —
Fuel injector return tube banjo bolts with copper sealing washer 38 28 —
Fuel injector return tube banjo bolts with Viton® sealing washers 25 18 —
Fuel injector return tube bracket bolts 13 — 115
Fuel injector return tube bracket nut 11 — 97
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Fuel injector return tube check valve 45 33 —
Fuel injector return tube fitting 38 28 —
Fuel injector supply tube fittings

a — — —
a
Fuel rail bolts — — —
Fuel rail supply tube bracket bolts 13 — 115
Fuel rail supply tube fittings

a — — —
Heater core return tube bolts 13 — 115

Heater core supply tube bolts and nut 13 — 115
High-pressure fuel injection pump bolts 61 45 —
High-pressure fuel injection pump cover bolts 13 — 115
High-pressure fuel injection pump gear bolt b 77 57 —
High-pressure fuel injection pump heat shield bolts and nuts 13 — 115
High-pressure pump test adapter (303-765) 12 — 106
LH high-pressure fuel injection pump heat shield nuts 7 — 62
Power steering hose retaining nut 25 18 —
Power steering pump bolts 25 18 —
Thermostat housing collar bolts 13 — 115
Throttle Body (TB) adapter bolts 10 — 89
TB bolts 10 — 89
Turbocharger heat shield bolts 11 — 97
Turbocharger inlet pipe-to-exhaust manifold nuts

a — — —
Turbocharger inlet pipe-to-turbocharger bolts

a — — —
Turbocharger oil feed tube banjo bolts with copper sealing washer 38 28 —
Turbocharger oil feed tube banjo bolts with Viton® sealing washer 25 18 —
Turbocharger oil feed tube bolt 13 — 115
Turbocharger-to- downpipe clamp

a — — —
Pipe Plugs
1/8 x 27 9 — 80
1/4 x 18 21 15 —
2008 F-250, 350, 450, 550 Super Duty, 7/2007

SPECIFICATIONS (Continued)
Torque Specifications (Continued)

1/2 x 14 36 27 —
3/8 x 18 37 27 —
a Refer to the procedure in this section.
b LH thread
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-04C-i Fuel Charging and Controls — 6.4L Diesel 303-04C-i

CONTENTS PAGE
DESCRIPTION AND OPERATION

Fuel Charging and Controls ............................................................................................................................................. 303-04C-2
System Cleanliness ................................................................................................................................................... 303-04C-2
Fuel System ............................................................................................................................................................... 303-04C-2
High-Pressure Fuel Pump Cover and Gasket ..................................................................................................... 303-04C-6
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

DESCRIPTION AND OPERATION

Fuel Charging and Controls
System Cleanliness
The common rail fuel injection system consists of components manufactured to precise tolerances. It is critical to make sure of absolute cleanliness during
all servicing of the common rail fuel injection system. Attention to cleanliness must also be followed when storing and handling parts. Use of lint-free rags is
required while servicing the fuel system. Clean high-pressure joints and surrounding area before removing any high-pressure tube or components. Fuel
System Caps must be used when any high-pressure fuel tube is serviced. Make sure system components and joints are clean prior to assembly.
Fuel System
WARNING:
Avoid contact with fuel during a visual inspection for fuel leaks with the engine running. Do not work on the fuel system until the pressure has been
released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts
and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.
NOTICE:
Before disconnecting any part of the fuel system, it is important that all dust, dirt and foreign material is removed from around components to
prevent ingress of foreign matter into the fuel system or the vehicle may be damaged.
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NOTICE:
The fuel tubes between the pump and the fuel rail, and the fuel rail and the injectors, must be discarded after each use and new tubes installed or
the vehicle may be damaged.
NOTICE:
It is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifice or
tubes, or the vehicle may be damaged.
NOTICE:
Make sure that the workshop area in which the vehicle being worked on is as clean and dust-free as possible. Areas in which work on clutches,
brakes or where welding or machining are carried out are not suitable due to the risk of contamination to the fuel system. Failure to follow this
instruction may result in damage to the vehicle.
NOTICE:
Use a steel-topped work bench or cover it with clean, lint-free, non-flocking material. Failure to follow this instruction may result in damage to the
vehicle.
NOTICE:
Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.
NOTICE:
Use only banjo bolts with a green hex head. Failure to install the correct banjo bolt may result in damage to the fuel system.
The high-pressure common rail fuel system used on the 6.4L direct injection turbocharged diesel engine is controlled electronically by the PCM. The high-
pressure fuel is delivered by the use of piezo-actuated fuel injectors.
The fuel system components consist of the following:
• Engine fuel filter module

• High-pressure fuel injection pump
• Pressure control valve (serviced with pump assembly)
• Volume control valve (serviced with pump assembly)
• High-pressure fuel rail
• Fuel Rail Pressure (FRP) sensor
• Piezo-actuated fuel injectors
• High-pressure fuel tubes
• Fuel injector and high-pressure fuel injection pump fuel return tubes and check valve
Fuel to be supplied to the combustion chamber passes through the horizontal fuel conditioning module into the engine fuel filter module. The low-pressure
filtered fuel enters the high-pressure fuel injection pump, which is then transferred to and stored in the fuel rails. The PCM-controlled, high-pressure fuel
injection pump generates pressures up to 170 kPa (24,650 psi) at rated horsepower. The storage of high-pressure fuel makes it possible to provide a constant
injection pressure regardless of the quantity of fuel required or the engine speed. The injection parameters are:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

DESCRIPTION AND OPERATION (Continued)
• Injection pressure
• Number of injections
• Timing of injections
• Injection quantity
These parameters are utilized for each injection phase within the piston cycle. This system uses pre-injection (pilot), main-injection and post-injection to
meet engine operating criteria:
• Engine system emissions

• Combustion noise reduction
• Engine performance
High-Pressure Fuel System Flow
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• Fuel is sent to the high-pressure fuel injection pump via the horizontal fuel conditioning module and fuel filter module, which filters the fuel.
• The high-pressure fuel injection pump is gear driven by the camshaft gear at the rear of the engine.
• Once the high-pressure fuel injection pump pressurizes the fuel it is routed to 2 steel tubes, one for each bank.
• The steel tubes route the fuel to the high-pressure fuel rail via a fitting that extends through the valve cover carrier.
• The high-pressure fuel rail routes fuel to each of the 4 injectors via 4 separate steel fuel tubes.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

High-Pressure Fuel Injection Pump
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Item Part Number Description
1 — RH fuel rail supply tube fitting
2 — Fuel filter module-to-high-pressure fuel injection pump tube fitting
3 — Pressure control valve
4 — LH fuel rail supply tube fitting
5 — High-pressure fuel injection pump-to-fuel cooler tube fitting
6 — Volume control valve
The high-pressure fuel injection pump is mounted in the rear of the engine valley and is driven by the camshaft gear. The high-pressure fuel injection pump
is serviced as an assembly only. The high-pressure fuel injection pump gear is fastened to the pump and fastened using a LH-threaded fastener.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Piezo Actuated Fuel Injector
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1 — Fuel injector piezo actuator
2 — High-pressure fuel inlet
3 — Low-pressure fuel return-to-cylinder galley
4 — Soft steel combustion gasket
5 — Fuel injector electrical connector
6 — Fuel injector O-ring seal
• The injector has a replaceable O-ring seal on the outside of the body and a replaceable soft steel combustion gasket on the tip of the injector.
• The injector's piezo actuator has a 2-pin connector that is located under the valve cover.
• The fuel charging wiring harness has a single main connection point at the front of the valve cover base.
The injectors are controlled by the PCM via an internal injector driver. The fuel injectors are electrically connected to the PCM via the fuel charging wiring
harness located under the valve cover. The fuel charging wiring harness is candy striped to provide a visual identification of high voltage, 80 to 200V. The
injectors use a piezo actuator instead of a solenoid to control injection. The piezo actuator provides an accurate control of injection timing and quantity per
piston cycle. The fuel injectors contain 6 orifices that provide an extremely fine fuel spray into the combustion chamber. The PCM controlled fuel injector
injects fuel into the combustion chamber at pressures up to 170 kPa (24,650 psi) at rated horsepower. Handle components with extreme care when servicing.
The fuel injector fits into a sleeved bore machined into the cylinder head. The injector bore intersects with a machined fuel return passage that runs the
length of the cylinder head. Low-pressure fuel return from the injectors flows through the cylinder head passage and joins the high-pressure fuel injection
pump-to-fuel cooler return tube in the valley of the engine. The fuel return travels through the engine fuel cooler, to reduce fuel temperature to the fuel filter
module, where the fuel is filtered and returned to the high-pressure injection pump or returned back to the fuel tank (depending on engine demand). Each
injector contains an O-ring seal around the outer body, above the fuel passage. All injectors have a combustion gasket to seal combustion gases from
entering the fuel return passage or the crankcase and to prevent fuel from entering the crankcase.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

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1 — High-pressure delivery connection
2 — Fuel return
3 — Wiring harness connector
4 — Piezo actuator
5 — Valve piston
6 — Valve mushroom
7 — Control piston
8 — Nozzle needle
9 — Nozzle
10 — Spray hole (6 each)
High-Pressure Fuel Pump Cover and Gasket

The high-pressure fuel injection pump cover fastens to the engine block at the rear of the engine valley. There are 2 gaskets, the upper and the lower pump
cover gaskets. The upper pump cover gasket seals the pump cover to the top of the pump. The lower gasket, which contains an integrated electrical harness
to support the pressure control valve and the volume control valve, seals the pump cover to the cylinder block and rear cover. When removing the fuel pump
cover, always install new upper and lower gaskets. After removing the high-pressure fuel tubes, it is crucial that the Fuel System Caps are installed on the
high-pressure pump ports. When reassembling the pump cover, make sure the upper gasket is located in the pump cover groove. RTV Silicone Sealant
TA-31 must be correctly applied to the engine block-to-rear cover junctions (2 locations) when assembling the lower pump cover gasket. Visually inspect
the wire routing of the lower gasket integrated circuit to make sure that the wires do not overlay the sealing bead during assembly.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
DIAGNOSIS AND TESTING

Fuel Charging and Controls ............................................................................................................................................. 303-04C-2
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

DIAGNOSIS AND TESTING

Fuel Charging and Controls
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
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2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
GENERAL PROCEDURES
Fuel Injection Pump Fitting Re-Torque ............................................................................................................................ 303-04C-2
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

GENERAL PROCEDURES
Fuel Injection Pump Fitting Re-Torque
Special Tool(s)
Caps, Fuel System

310-158
Material
Item Specification
Metal Brake Parts Cleaner —
PM-4-A or PM-4-B (US); CPM-4 (Canada)
1. NOTE:
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The fuel tubes must be removed in order to tighten the fitting(s).
NOTE:
Always cap open fuel system components to prevent debris or contamination from entering the fuel system.
Install the fuel system caps on the high-pressure fuel injection pump fittings.
2. NOTE:
Do not remove the fitting(s) from the high-pressure fuel injection pump.
Finger tighten the loose fitting(s).

3. NOTE:
Do not flush the top of the high-pressure fuel injection pump.
NOTE:
Do not use shop air around the fittings.
NOTE:
Do not use spray cleaners to clean the top of the high-pressure fuel injection pump.
Clean the top of the high-pressure fuel injection pump at the base of the fittings with a clean towel dampened with metal brake parts cleaner.
4. NOTE:
Fuel System Caps removed from art for clarity.
NOTE:
Use a deep well socket over the fuel system caps to tighten the fitting(s).
If necessary, tighten the high pressure fitting(s).

• Tighten to 45 Nm (33 lb-ft).
2008 F-250, 350, 450, 550 Super Duty, 7/2007

GENERAL PROCEDURES (Continued)
5. NOTE:
Fuel System Caps removed from art for clarity.
NOTE:
Use a deep well socket over the fuel system caps to tighten the fitting(s).
If necessary, tighten the low pressure fitting(s).

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2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
GENERAL PROCEDURES
Cylinder Head Fuel Passage Flushing ............................................................................................................................. 303-04C-2
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

GENERAL PROCEDURES
Cylinder Head Fuel Passage Flushing
Special Tool(s)
Adapter, High-Pressure Pump Test

303-765
Material
Item Specification
Motorcraft® SAE 15W-40 Super Duty Diesel Motor Oil WSS-M2C171-E
XO-15W40-QSD (US); CXO-15W40-LSD12 (Canada)
1. NOTICE:
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Do not flush both cylinder heads at the same time, there will not be adequate fuel volume to clean out the debris from the cylinder head fuel
passages.
NOTE:
Leave the original fuel injectors in the cylinder head until the cylinder head fuel passage flushing is complete.
NOTE:
Use a ORFS/NPF fitting such as a Aeroquip FF2031T0606S or Gates G60770-0606 for the fuel injector return tube.
Install commercially available fittings to the fuel injector return tube.

• Tighten the fuel injector return tube fitting to 38 Nm (28 lb-ft).
2. Remove the LH cylinder head fuel passage plug.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

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3. Install the High-Pressure Pump Test Adapter into the LH cylinder head fuel passage.
• Tighten to 12 Nm (106 lb-in).
4. Attach a fitting and rubber hose to the High-Pressure Pump Test Adapter.
• Position the other end of the rubber hose over a sheet of paper towel and a clear container.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

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5. NOTE:
Do not exceed 55.2 kPa (8 psi) of fuel pressure during flushing.
Using a suction gun filled with new filtered diesel fuel, flush the LH cylinder head fuel passage.
• Inspect the paper towel for debris.
• Repeat a second time, if necessary.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

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6. Remove the rubber hose from the High-Pressure Pump Test Adapter.
7. Remove the High-Pressure Pump Test Adapter from the LH cylinder head fuel passage.
8. NOTE:
Inspect the cylinder head fuel passage plug gasket for damage, replace if necessary.
NOTE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Apply clean engine oil to the cylinder head fuel passage plug gasket prior to installation.
Install the LH cylinder head fuel passage plug.

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9. Remove the RH cylinder head fuel passage plug.
10. Install the High-Pressure Pump Test Adapter into the RH cylinder head fuel passage.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

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11. Attach a rubber hose to the High-Pressure Pump Test Adapter.
• Position the other end of the rubber hose over a sheet of paper towel and a clear container.
12. NOTE:
Do not exceed 55.2 kPa (8 psi) of fuel pressure during flushing.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Using a suction gun filled with new filtered diesel fuel, flush the RH cylinder head fuel passage.
• Inspect the paper towel for debris.
• Repeat a second time, if necessary.
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13. Remove the rubber hose and fitting from the High-Pressure Pump Test Adapter.
14. Remove the High-Pressure Pump Test Adapter from the RH cylinder head fuel passage.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

15. NOTE:
Inspect the cylinder head fuel passage plug gasket for damage, replace if necessary.
NOTE:
Apply clean engine oil to the cylinder head fuel passage plug gasket prior to installation.
Install the RH cylinder head fuel passage plug.

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16. Remove the commercially available fittings from the fuel injector return tube.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

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17. NOTE:
Use a socket over the stud to position the fuel injection pump-to-fuel cooler return tube in a vise.
Remove the check valve from the fuel injection pump-to-fuel cooler return tube.
• Clean the debris from the check valve as needed.
18. Using a suction gun filled with new filtered diesel fuel, flush the fuel injection pump-to-fuel cooler return tube until clean and debris free.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

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19. NOTE:
Apply clean engine oil to the check valve O-ring prior to installation.
Install the check valve into the fuel injection pump-to-fuel cooler return tube.
20. Remove the banjo bolt and the fuel cooler-to-fuel filter module return tube.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

• Discard the sealing washers.
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21. NOTE:
Use a fitting from the high-pressure fuel injection pump and rubber hose to flush the fuel cooler-to-fuel filter module return tube.
Using a suction gun filled with new filtered diesel fuel, flush the fuel cooler-to-fuel filter module return tube until clean and debris free.
22. Using new sealing washers, install the fuel cooler-to-fuel filter module return tube and the banjo bolt.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

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23. Replace the fuel cooler. For additional information, refer to Section 303-04E.
24. Replace the fuel filters. For additional information, refer to Section 310-01.
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CONTENTS PAGE
Fuel Injectors .................................................................................................................................................................... 303-04C-2
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fuel Injectors
Special Tool(s)
Caps, Fuel System

310-158
Cups, Fuel Injector

303-1261
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Holding Rack, Fuel Injector
303-D114 (D94T-9000-E1)
Tool, Fuel Injector Connector Disconnect

310-157
Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software
with appropriate hardware, or equivalent scan tool
Material
Item Specification
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(Continued)
RH Fuel Injectors
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1 9A555 Fuel rail-to-fuel injector tube (4 required)
2 — Fuel injector electrical connector (part of 9D930) (4 required)
3 9C995 Fuel injector hold-down clamp assembly (4 required)
4 — Fuel injector (4 required)
5 — Fuel injector O-ring seal (4 required)
6 — Combustion gasket (4 required)
7 — Fuel Rail Pressure (FRP) sensor electrical connector (part of 9D930)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
LH Fuel Injectors
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1 9A555 Fuel rail-to-fuel injector tube (4 required)
3 9C995 Fuel injector hold-down clamp assembly (4 required)
4 — Fuel injector (4 required)
5 — Fuel injector O-ring seal (part of 1874846) (4 required)
6 — Combustion gasket (part of 1874846) (4 required)
Removal
1.
WARNING:
Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot
and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these
instructions may result in serious personal injury.
Shut the engine off and wait until the engine is cool or 5 minutes, whichever is longer, to allow the high-pressure fuel system pressure to bleed off and
the fuel to cool.
2. Remove the LH or RH valve cover. For additional information, refer to Section 303-01C.
3.
WARNING:
Contact with exposed fuel injector wiring, if energized, may result in electric shock. Use care when working on or around energized fuel
injector wiring. Fuel injector wiring supplies high voltage to operate the fuel injectors. Failure to follow this instruction may result in serious
personal injury.
Make sure the ignition switch is in the OFF position.

4. Using the Fuel Injector Connector Disconnect Tool, disconnect the fuel injector electrical connector.
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(Continued)
5. If necessary, disconnect the Fuel Rail Pressure (FRP) sensor electrical connector.
6. NOTICE:
Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage it is essential that
absolute cleanliness is observed when working with these components. Always install Fuel System Caps on any open orifices or tubes.
NOTE:
Use a back-up wrench on the fuel injector fittings.
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Remove and discard the fuel injector supply tube.
7. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
8. NOTICE:
Failure to account for all fuel injector hold-down clamp assembly bolt retainers or pieces of retainers prior to placing the vehicle back in
service may cause engine damage. A missing retainer can be ingested into the lube oil system causing severe engine damage.
NOTICE:
To prevent engine damage, do not use air tools to remove the fuel injectors. The fuel injector hold-down clamp assembly bolt retainer that
extracts the injector can dislodge and fall into the oil drain hole.
NOTE:
There is no need to drain the fuel rail.
NOTE:
If engine coolant is found in the combustion chambers, it may be necessary to install a new injector sleeve.
Loosen the bolt, and remove the fuel injector hold-down clamp assembly and the fuel injector.
• Remove and discard the O-ring seal and soft steel combustion gasket.
9. Install a Fuel Injector Cup on the fuel injector nozzle and store the fuel injector in the Fuel Injector Holding Rack.
10. NOTE:
If a fuel injector hold-down clamp assembly bolt retainer or piece of a retainer is missing from the fuel injector hold-down clamp assembly, it must be
located prior to removing the shop towels.
Remove the shop towels.
Installation
1. NOTE:
Lubricate the fuel injector and O-ring seal with clean engine oil.
Install a new O-ring seal and a soft steel combustion gasket on the fuel injector.
• Make sure the bead on the soft steel combustion gasket is facing the cylinder head.
2. NOTICE:
Failure to tighten the injector correctly can lead to engine failure.
NOTICE:
To prevent engine damage, do not use air tools to install the fuel injectors. The fuel injector hold-down clamp bolt retainer that extracts the
injector can dislodge and fall into the oil drain hole.
NOTICE:
If the fuel injector hold-down clamp assembly bolt retainer is damaged or missing, a new fuel injector hold-down clamp assembly must be
installed, or the clamp assembly will not be able to remove the fuel injector.
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(Continued)
Install the fuel injector, the fuel injector hold-down clamp assembly and the bolt.
3. NOTE:
NOTE:
Use a crowfoot wrench to aid in tightening the fuel injector supply tube.
Install the new fuel injector supply tube in the following sequence.
1 Remove the Fuel System Caps from the high-pressure fuel rail and the fuel injector one at a time prior to assembly of each tube.
2 Position the new fuel injector supply tube between the high-pressure fuel rail and fuel injectors and fully hand-start and seat the tube fittings onto
the mating high-pressure fuel rail and fuel injector high-pressure connectors. Snug the fuel injector supply tube fittings using the inside-out step
sequence (the 2 inside tubes then the 2 outside tubes).
▪ Calculate the correct torque wrench setting for the following torque. Refer to the Torque Wrench Adapter Formulas in the Appendix.
▪ Using a torque adapter, tighten to 2 Nm (18 lb-in).
3 Tighten the fuel injector hold-down clamp bolt.
▪ Tighten to 38 Nm (28 lb-ft).
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4 NOTE:
Pre-tighten the fuel injector fitting first, then the fuel rail fitting.
Pre-tighten the fuel injector supply tube fittings.

5 NOTE:
Place a visible mark with a permanent marker on the high-pressure fuel rail and fuel injector threaded connection. Turning the tube fittings one
flat of the nut is equal to 60 degrees.
Final tighten the fuel injector supply tube fittings.

▪ Tighten the fittings 60 degrees.
4. If necessary, connect the FRP sensor electrical connector.
5. Connect the fuel injector electrical connector.
6. Install the LH or RH valve cover. For additional information, refer to Section 303-01C.
7. Bleed the high-pressure fuel system. For additional information, refer to Section 310-00.
8. NOTE:
Clearing the DTCs or Keep Alive Memory (KAM) does not reset the adaptive values in the PCM.
If fuel injector(s) were replaced, clear the fuel injector adaptive tables from the PCM, using the scan tool. For additional information, refer to the
Powertrain Control/Emissions Diagnosis (PC/ED) manual.
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CONTENTS PAGE
Fuel Charging Wiring Harness ......................................................................................................................................... 303-04C-2
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fuel Charging Wiring Harness

Special Tool(s)
Tool, Fuel Injector Connector Disconnect

310-157
Charge Air Cooler (CAC) Tube Flex Connector
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1 6K786 Charge Air Cooler (CAC) tube flex coupling clamp (tube end)
2 6K786 CAC tube flex coupling clamp (engine end)
3 6W650 CAC tube flex coupling
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(Continued)
Upper Radiator Hose
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1 — Upper radiator hose spring clip (part of 8B274)
2 8B274 Upper radiator hose
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
RH Fuel Charging Wiring Harness
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2 — Fuel Rail Pressure (FRP) sensor electrical connector (part of 9D930)
3 — Fuel charging wiring harness electrical connector (part of 12A581)
4 9D930 Fuel charging wiring harness
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
LH Fuel Charging Wiring Harness
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2 — Fuel charging wiring harness electrical connector (part of 12A581)
3 9D930 Fuel charging wiring harness
Removal
Both sides
1. Remove the LH or RH valve cover. For additional information, refer to Section 303-01C.
LH side
2. Drain the cooling system. For additional information, refer to Section 303-03.
3. Loosen the clamps and remove the Charge Air Cooler (CAC) tube flex coupling.
4. Remove the clip and disconnect the upper radiator hose from the thermostat housing. Position the upper radiator hose aside.
RH side
5. Disconnect the Fuel Rail Pressure (FRP) sensor electrical connector.
Both sides
6.
WARNING:
Contact with exposed fuel injector wiring, if energized, may result in electric shock. Use care when working on or around energized fuel
injector wiring. Fuel injector wiring supplies high voltage to operate the fuel injectors. Failure to follow this instruction may result in serious
personal injury.
Make sure the ignition switch is in the OFF position.

7. Using the Fuel Injector Connector Disconnect Tool, disconnect the fuel injector electrical connectors. Detach the fuel charging wiring harness from
the fuel rail.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
8. Disconnect the fuel charging wiring harness electrical connector.

9. NOTE:
The terminals in the fuel charging wiring harness plug are not serviceable. Install a new fuel charging wiring harness if the terminals are damaged.
Remove the fuel charging wiring harness electrical connector from the valve cover base and remove the fuel charging harness.
Installation
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Both sides
1. Position the fuel charging wiring harness and install the fuel charging wiring harness electrical connector into the valve cover base.
2. Connect the fuel charging wiring harness electrical connector.
3. Attach the fuel charging wiring harness to the fuel rail and connect the fuel injector electrical connectors.
RH side
4. Connect the FRP sensor electrical connector.
LH side
5. Install the upper radiator hose and the spring clip.
• Make sure the spring clip is installed correctly.
6. Install the CAC tube flex coupling and tighten the clamps.
• Tighten the engine clamp to 12 Nm (106 lb-in).
• Tighten the tube clamp to 8 Nm (71 lb-in).
7. Fill and bleed the cooling system. For additional information, refer to Section 303-03.
Both sides
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Fuel Filter Module ............................................................................................................................................................ 303-04C-2
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fuel Filter Module

Special Tool(s)
Caps, Fuel System

310-158
Charge Air Cooler (CAC) Tube Flex Coupling
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Wiring Harness Attaching Points
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1 W300003 Wiring harness bolt
2 — Wiring harness retainer (part of 12A581)
4 — Fuel temperature sensor electrical connector (part of 12A581)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Fuel Filter Module
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1 — Fuel filter module cover
2 9C330 Fuel injection pump supply tube
3 W301558 Fuel filter module supply tube banjo bolt (M14)
4 W302475 Fuel filter module supply tube copper sealing washer (shown in art)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

4 W303692 Fuel filter module supply tube Viton® sealing washer (2 required)
(not shown)
5 9B273 Fuel filter module supply tube
6 W302472 Fuel filter module return tube banjo bolts (M12) (2 required)
7 W302474 Fuel filter module return tube copper sealing washers (2 required)
(shown in art)
7 W303659 Fuel filter module return tube Viton® sealing washers (4 required)
(not shown)
8 9C273 Fuel filter module return tube
9 9D309 Fuel cooler-to-fuel filter module return tube
10 W300015 Fuel filter module bolts (2 required)
11 W302477 Fuel filter module stud bolt
12 — Fuel filter module
Removal
1. Remove the vertical EGR cooler. For additional information, refer to Section 303-08.
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2. Remove the engine wiring harness bolt.
3. Disconnect the wiring harness retainer from the engine lifting bracket.
4. Disconnect the fuel temperature sensor electrical connector.
5. Disconnect the wiring harness retainer from the fuel filter module stud bolt.
6. NOTICE:
absolute cleanliness is observed when working with these components.
Remove the fuel filter module cover and, using a suitable suction device, remove the fuel from the fuel filter module.
• Install the fuel filter module cover when finished.
8. NOTICE:
Remove the 3 banjo bolts and 3 sealing washers, and detach the fuel tubes from the fuel filter module.
• Plug or cap the openings and tubes as needed.
9. Remove the 2 fuel filter module bolts and stud bolt.
10. NOTICE:
Position the fuel filter module to access and, using a commercially available disconnect tool, disconnect the fuel injection pump supply tube. Remove
the fuel filter module.
• Plug or cap the opening and tube as needed.
Installation
1. Connect the fuel injection pump supply tube and position the fuel filter module.
2. Install the 2 fuel filter module bolts and stud bolt.
3. NOTICE:
Use only banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the
correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the fuel system.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Position the fuel filter module return tubes and install new sealing washers and the banjo bolts (M12).
• For Viton® sealing washers, tighten to 25 Nm (18 lb-ft).
• For a copper sealing washer, tighten to 38 Nm (28 lb-ft).
4. NOTICE:
Position the fuel filter module supply tube and install new sealing washers and the banjo bolt (M14).
• For copper sealing washer, tighten to 47 Nm (35 lb-ft).
5. Install the CAC tube flex coupling and tighten the clamps.
6. Position the wiring harness retainer on the fuel filter module stud bolt.
7. Connect the fuel temperature sensor electrical connector.
8. Connect the wiring harness retainer to the engine lifting bracket.
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9. Install the engine wiring harness bolt.
10. Install the vertical EGR cooler. For additional information, refer to Section 303-08.
11. Bleed the low-pressure fuel system. For additional information, refer to Section 310-00.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Fuel Injection Pump — High Pressure, Body Off .............................................................................................................. 303-04C-2
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fuel Injection Pump — High Pressure, Body Off

Special Tool(s)
Caps, Fuel System

310-158
Dial Indicator Gauge with Holding Fixture

100-002 (TOOL-4201-C)
cardiagn.com
Material
Item Specification
RTV Silicone Sealant —
TA-31
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Glow Plug Module Heat Shield
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1 — Glow plug module heat shield pushnuts
2 — Glow plug module heat shield
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
High-Pressure Fuel Injection Pump Heat Shields
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1 W705790 Engine-to-body ground wire nut
2 19A095 Engine-to-body ground wire
3 W300049 RH high-pressure fuel injection pump heat shield nut
4 W301401 RH high-pressure fuel injection pump heat shield bolts (2 required)
5 — RH high-pressure fuel injection pump heat shield bolt
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

6 9G478 RH high-pressure fuel injection pump heat shield
7 W300049 LH high-pressure fuel injection pump heat shield nuts (3 required)
8 9180 Fuel tube bracket
9 9G478 LH high-pressure fuel injection pump heat shield
Fuel Rail Supply Tubes
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1 — High-pressure fuel injection pump electrical connector (part of
9F759)
2 — Fuel injector return tube fitting (part of 9C273)
3 W300002 Fuel rail supply tube bracket bolts (2 required)
4 9A332 LH fuel rail supply tube
5 9A332 RH fuel rail supply tube
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
High-Pressure Fuel Injection Pump Supply and Return Tubes
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1 W300049 Fuel injection pump supply tube bracket nuts (2 required)
2 W302473 Fuel tube-to-high-pressure fuel injection pump nuts (2 required)
3 W302474 Fuel tube-to-high-pressure fuel injection pump copper sealing
washers (2 required) (shown in art)
3 W303659 Fuel tube-to-high-pressure fuel injection pump Viton® sealing
washers (4 required) (not shown)
5 9D309 Fuel injection pump-to-fuel cooler return tube
High-Pressure Fuel Injection Pump Cover
NOTE:
Turbocharger assembly removed from art for clarity.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
cardiagn.com
1 W300014 High-pressure fuel injection pump cover bolts (5 required)
2 9A413 High-pressure fuel injection pump cover
3 6619 High-pressure fuel injection pump cover press-in-place gasket
4 — Volume control valve electrical connector (part of 6619)
5 — Pressure control valve electrical connector (part of 6619)
6 6619 High-pressure fuel injection pump cover gasket
NOTE:
Turbocharger assembly removed from art for clarity.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
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1 W300935 High-pressure fuel injection pump bolts (3 required)
2 9A543 High-pressure fuel injection pump
3 W302470 High-pressure fuel injection pump gear bolt (LH thread)
4 W302471 High-pressure fuel injection pump gear washer
5 9F589 High-pressure fuel injection pump gear
Removal
NOTE:
It is recommended that this component be serviced with the vehicle body removed. If the body cannot be removed, refer to Fuel Injection Pump — High
Pressure, Body On in this section.
1.
WARNING:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
the fuel to cool.
2. Remove the turbocharger inlet pipes. Carry out the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) Turbocharger Inlet Pipes
— 6.4L, Body Off procedure. For additional information, refer to Section 309-00.
3. Remove the 3 pushnuts and the glow plug module heat shield.
• Discard the pushnuts.
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4. Remove the 3 RH high-pressure fuel injection pump heat shield bolts.
5. Remove the 2 RH high-pressure fuel injection pump heat shield nuts and position the engine-to-body ground wire aside. Remove the RH high-
pressure fuel injection pump heat shield.
6. Remove the 3 nuts, the fuel tube bracket and the LH high-pressure fuel injection pump heat shield.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
7. Remove the 2 fuel rail supply tube bracket bolts.
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8. NOTICE:
absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.
NOTE:
Use a back-up wrench to prevent the fittings in the high-pressure fuel injection pump from turning. If the fittings move, the high-pressure fuel
injection pump fittings must be retightened. Refer to Fuel Injection Pump Fitting Re-Torque in this section.
NOTE:
It will be necessary to use a thin or low profile wrench to hold the fittings on the high-pressure fuel injection pump.
NOTE:
LH side shown, RH side similar.
Remove and discard the fuel rail supply tubes.
9. Disconnect the high-pressure fuel injection pump electrical connector.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
10. NOTICE:
Disconnect the fuel injector return tube fitting from the check valve.
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11. Loosen the 2 high-pressure fuel injection pump supply tube bracket nuts.
12. NOTICE:
NOTE:
NOTE:
Remove the fuel tube-to-high-pressure fuel injection pump nuts and the sealing washers. Remove the fuel injection pump-to-fuel cooler return tube
and position the fuel supply tube aside.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
13. NOTE:
Rotate the cover to the right when removing the cover.
Remove the 5 bolts and the high-pressure fuel injection pump cover.
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14. Remove and discard the press-in-place gasket from the high-pressure fuel injection pump cover.
15. Disconnect the pressure control valve and volume control valve electrical connectors.
16. NOTE:
Use a thin gasket scraper to separate the gasket from the crankcase.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Remove and discard the high-pressure fuel injection pump cover gasket.
17. Position the Dial Indicator Gauge and Holding Fixture and check the high-pressure fuel injection pump drive gear backlash.
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18. Remove the 3 bolts and the high-pressure fuel injection pump.
19. NOTE:
The high-pressure fuel injection pump drive gear bolt is a LH thread.
If a new pump is being installed, remove the bolt, the washer and the high-pressure fuel injection pump gear.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Installation
1. NOTICE:
The protruding hub of the high-pressure fuel injection pump drive gear must be facing the high-pressure fuel injection pump. Failure to
install the gear correctly will result in engine damage.
NOTE:
NOTE:
The high-pressure fuel injection pump gear bolt will not be tightened at this time.
If a new pump is being installed, install the high-pressure fuel injection pump drive gear, washer and bolt.
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2. Install the high-pressure fuel injection pump and the 3 bolts.
3. NOTE:
The high-pressure fuel injection pump gear bolt has a LH thread.
NOTE:
Use a tool such as a Snap-On® FRDHM15 torque adapter, or equivalent, to tighten the bolt.
If a new high-pressure fuel pump has been installed, tighten the gear bolt.
• Calculate the correct torque wrench setting for the following torque. Refer to the Torque Wrench Adapter Formulas in the Appendix.
• Using a torque adapter, tighten to 77 Nm (57 lb-ft).
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
4. Using the Dial Indicator Gauge with Holding Fixture, check the high-pressure fuel injection pump drive gear backlash.
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5. Clean the cover mounting surface and apply a dime-sized bead of sealant at the seams.
6. NOTICE:
Inspect the volume control valve and the pressure control valve electrical connectors for damage or obstructions at the connector and mating
high-pressure fuel injection pump connector. Verify that the connectors are completely latched to the valve housings or engine damage may
occur.
Install a new high-pressure fuel injection pump cover gasket. Connect the pressure control valve and volume control valve electrical connectors.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
7. Install a new press-in-place gasket in the high-pressure fuel injection pump cover.
8. NOTE:
Do not remove the Fuel System Caps from the high-pressure fuel injection pump until the fuel tubes are being installed.
Install the high-pressure fuel injection pump cover and the 5 bolts.
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9. NOTE:
If there is metal debris in the high-pressure fuel system, flush the cylinder head fuel passages and the return tubes. For additional information, refer to
Cylinder Head Fuel Passage Flushing in this section.
NOTE:
NOTE:
NOTE:
Use a crowfoot wrench to aid in tightening the fitting.
Install new sealing washers, the fuel tubes and the nuts to the high-pressure fuel injection pump.
• For Viton® sealing washers, using a torque adapter, tighten to 25 Nm (18 lb-ft).
• For copper sealing washer, using a torque adapter, tighten to 38 Nm (28 lb-ft).
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
10. Tighten the 2 fuel injection pump supply tube bracket nuts.
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11. NOTE:
Connect the fuel injector return tube fitting to the check valve.
12. Connect the high-pressure fuel injection pump electrical connector.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
13. NOTE:
NOTE:
NOTE:
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Use a crowfoot wrench to aid in tightening the fuel rail supply tube.
NOTE:
LH side shown, RH side similar.
Install the new fuel rail supply tubes one at a time in the following sequence.
1 Remove only the Fuel System Caps from the fuel rail supply tube openings being serviced.
2 NOTE:
Support the tubes while hand snugging the nut to make sure of correct assembly of the joints.
Position the new fuel rail supply tubes between the high-pressure fuel injection pump and high-pressure fuel rail. Fully hand start and seat the 4
fuel rail supply tube fittings onto the high-pressure fuel injection pump and high-pressure fuel rails.
3 Snug the 4 fuel rail supply tube fittings.
4 Pre-tighten the 4 fuel rail supply tube fittings.
5 NOTE:
Place a visible mark with a permanent marker on the 4 fuel rail supply tube threaded connections. Turning the fuel injector supply tube nuts one
flat of the fitting is equal to 60 degrees.
Final-tighten the 4 fuel rail supply tube fittings.

▪ Tighten the 4 fuel rail supply tube fittings 60 degrees.
14. Install the 2 fuel rail supply tube bracket bolts.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
15. NOTICE:
Failure to correctly install the heat shield may result in engine damage.
Install the LH high-pressure fuel injection pump heat shield, the fuel tube bracket and the 3 nuts.
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16. Install the RH fuel pump heat shield and position the engine-to-body ground wire. Install the 2 nuts.
17. Install the 3 high-pressure fuel injection pump heat shield bolts.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
18. Install the glow plug module heat shield and 3 new pushnuts.
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19. Install the turbocharger inlet pipes. Carry out the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) and Turbocharger Inlet Pipes
— 6.4L Diesel, Body Off procedure. For additional information, refer to Section 309-00.
20. Bleed the low-pressure and high-pressure fuel system. For additional information, refer to Section 310-00.
21. NOTE:
If the high-pressure fuel injection pump was replaced, clear the fuel injector adaptive tables from the PCM, using the scan tool. For additional
information, refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Fuel Injection Pump — High Pressure, Body On .............................................................................................................. 303-04C-2
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fuel Injection Pump — High Pressure, Body On

Special Tool(s)
Caps, Fuel System

310-158
Dial Indicator Gauge with Holding Fixture

100-002 (TOOL-4201-C)
cardiagn.com
Material
Item Specification
RTV Silicone Sealant —
TA-31
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
cardiagn.com
1 W302674 Glow plug module heat shield pushnuts
2 12A345 Glow plug module heat shield
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
High-Pressure Fuel Injection Pump Heat Shield
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Fuel Rail Supply Tubes
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9F759)
4 9A332 LH fuel supply tube
5 9A332 RH fuel supply tube
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
High-Pressure Fuel Injection Pump Supply and Return Tubes
cardiagn.com
1 W300049 High-pressure fuel injection pump supply tube bracket nuts (2
required)
2 W302473 Fuel tube-to-high-pressure fuel injection pump nuts (2 required)
3 W302474 Fuel tube-to-high-pressure fuel injection pump copper sealing
washers (2 required) (shown in art)
3 W303659 Fuel tube-to-high-pressure fuel injection pump Viton® sealing
washers (4 required) (not shown)
4 9C330 High-pressure fuel injection pump supply tube
5 9D309 High-pressure fuel injection pump-to-fuel cooler return tube
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
High-Pressure Fuel Injection Pump Cover
cardiagn.com
1 W300014 High-pressure fuel injection pump cover bolts (5 required)
2 9A413 High-pressure fuel injection pump cover
3 6619 High-pressure fuel injection pump cover press-in-place gasket
4 — Volume control valve electrical connector (part of 6619)
5 — Pressure control valve electrical connector (part of 6619)
6 6619 High-pressure fuel injection pump cover gasket
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
cardiagn.com
1 W300935 High-pressure fuel injection pump bolts (3 required)
2 9A543 High-pressure fuel injection pump
3 W302470 High-pressure fuel injection pump gear bolt (LH thread)
4 W302471 High-pressure fuel injection pump gear washer
5 9F589 High-pressure fuel injection pump gear
Removal
NOTE:
It is recommended that this component be serviced with the vehicle body removed. If the body can be removed, refer to Fuel Injection Pump — High
Pressure, Body Off in this section.
1.
WARNING:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Shut the engine off and wait until the engine is cool or 5 minutes, whichever is longer, to allow the high-pressure fuel system to bleed off and the fuel
to cool.
2. Remove the turbocharger. Carry out the Turbocharger — Body On procedure. For additional information, refer to Section 303-04D.
3. Remove the EGR-Oxidation Catalytic Converter (OC) pipe from the vehicle.
4. Remove the bolt and the 5 retaining nuts for the high-pressure fuel injection pump heat shield. Remove the fuel tube bracket and position aside the
ground wire.
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5. Remove the remaining 2 bolts and the high-pressure fuel injection pump heat shield.
6. Remove the RH turbocharger inlet pipe.
• In order to remove the RH turbocharger inlet pipe, roll it to the left side of the vehicle and then remove the RH turbocharger inlet pipe.
9. NOTICE:
Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that
NOTE:
NOTE:

10. NOTICE:
11. Remove the 2 high-pressure fuel injection pump supply tube bracket nuts.
12. NOTICE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
NOTE:
NOTE:
Remove the nuts and the sealing washers for the high-pressure fuel injection pump. Remove the high-pressure fuel injection pump supply tube and
fuel injection pump-to-cooler return tube.
14. Remove the 5 bolts and the high-pressure fuel injection pump cover.
15. Remove and discard the press-in-place gasket from the high-pressure pump cover.
16. NOTE:
Use a thin gasket scraper to separate the gasket from the crankcase.
Disconnect the pressure control valve and volume control valve electrical connectors. Remove and discard the high-pressure fuel injection pump
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cover gasket.
17. Using the Dial Indicator Gauge with Holding Fixture, check the high-pressure fuel injection pump drive gear backlash. For additional information,
refer to Specifications in this section.
18. Remove the 3 bolts and the high-pressure fuel injection pump.
19. NOTE:
If a new pump is being installed, remove the bolt, washer and the high-pressure fuel injection pump gear.
Installation
1. NOTICE:
The protruding hub of the high-pressure fuel injection pump drive gear must be facing the high-pressure fuel injection pump. Failure to
install the gear correctly will result in engine damage.
NOTE:
NOTE:
The high-pressure fuel injection pump gear bolt will not be tightened at this time.
If a new pump is being installed, install the high-pressure fuel injection pump drive gear, washer and bolt.
2. Install the high-pressure fuel injection pump and 3 bolts.
3. NOTE:
The high-pressure fuel injection pump gear bolt has a LH thread.
NOTE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Use a tool such as a Snap-On® FRDHM15 torque adapter, or equivalent, to tighten the bolt.
If a new high-pressure fuel injection pump has been installed, tighten the gear bolt.
4. Using the Dial Indicator Gauge with Holding Fixture, check the high-pressure fuel injection pump drive gear backlash. For additional information,
refer to Specifications in this section.
cardiagn.com
5. Clean the cover mounting surface and apply a dime-sized bead of sealant at the seams.
6. NOTICE:
Inspect the volume control valve and the pressure control valve electrical connectors for damage or obstructions at the connector and mating
high-pressure fuel injection pump connector. Verify that the connectors are completely latched to the valve housings or engine damage may
occur.
Install a new high-pressure fuel injection pump cover gasket. Connect the pressure control valve and volume control valve electrical connectors.
7. Install a new press-in-place gasket in the high-pressure fuel injection pump cover.
8. NOTE:
Do not remove the Fuel System Caps from the high-pressure fuel injection pump until the fuel tubes are being installed.
Install the high-pressure fuel injection pump cover and 5 bolts.

10. NOTE:
If there is metal debris in the high-pressure fuel system, flush the cylinder head fuel passages and the return tubes. For additional information, refer to
Cylinder Head Fuel Passage Flushing in this section.
NOTE:
NOTE:
Install new sealing washers, high-pressure fuel injection pump supply tube, fuel injection pump-to-cooler return tube and nuts at the high-pressure
fuel injection pump.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

11. Install the 2 high-pressure fuel injection pump supply tube bracket nuts.
12. NOTE:
Calculate the correct torque wrench setting for the following torque. Refer to the Torque Wrench Adapter Formulas in the Appendix.
13. NOTE:
NOTE:
NOTE:
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Install the new fuel rail supply tubes in the following sequence.
1 Remove the Fuel System Caps from the fuel rail supply tube openings.
2 NOTE:
Support the tubes while hand snugging the nut to make sure of correct assembly of the joints.
Position the fuel rail supply tubes between the high-pressure fuel injection pump and the high-pressure fuel rail. Fully hand start and seat the 4
fuel rail supply tube fittings onto the high-pressure fuel injection pump and high-pressure fuel rails.
3 Snug the 4 fuel rail tube fittings.
4 Pre-tighten the 4 fuel rail supply tube fittings.
5 NOTE:
Place a visible mark with a permanent marker on the 4 fuel rail supply tube nuts. Turning the fuel injector supply tube nuts one flat of the fitting
is equal to 60 degrees.
Final-tighten the fuel rail supply tube fittings.

▪ Tighten the 4 fuel rail supply tube fittings 60 degrees.
15. NOTE:
Use a socket to aid in installing the retainers.
Install the glow plug module heat shield and 3 new pushnuts.
16. Position the RH turbocharger inlet pipe in the vehicle.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
17. NOTICE:
Failure to correctly install the high-pressure fuel injection pump heat shield may result in engine damage.
Install the high-pressure fuel injection pump heat shield in the vehicle and install the 2 center bolts.
18. Position the fuel tube bracket and ground wire. Install the 5 retaining nuts and bolt for the high-pressure fuel pump shield.
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• Tighten the fuel line bracket nuts to 7 Nm (62 lb-in).
• Tighten the remaining fasteners to 13 Nm (115 lb-in).
19. Position the EGR-OC pipe in the vehicle.
20. Install the turbocharger. Carry out the Turbocharger — Body On procedure. For additional information, refer to Section 303-04D.
21. NOTE:
If the high-pressure fuel injection pump was replaced, clear the fuel injector adaptive tables from the PCM, using the scan tool. For additional
information, refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Fuel Injection Pump Supply Tube — Body On .................................................................................................................. 303-04C-2
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fuel Injection Pump Supply Tube — Body On

Special Tool(s)
Caps, Fuel System

310-158
cardiagn.com

2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

Fuel Injection Pump Supply Tube
cardiagn.com
2 W302473 Fuel injection pump supply tube-to-high-pressure fuel injection
pump nut
pump copper sealing washer (shown in art)
pump Viton® sealing washer (2 required) (not shown)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

Removal
NOTE:
It is recommended that this component be serviced with the vehicle body removed. If the body can be removed, refer to Fuel Injection Pump Supply Tube —
Body Off in this section.
1. Shut the engine off and wait 5 minutes to allow fuel in the fuel filter module to partially drain.
cardiagn.com
4. Remove the bolt and the 5 retaining nuts for the high-pressure fuel injection pump heat shield. Remove the fuel tube bracket and position the ground
wire.
6. Remove the 2 high-pressure fuel injection pump supply tube bracket nuts.
7. NOTICE:
NOTE:
NOTE:
Remove the high-pressure fuel injection pump supply tube-to-high-pressure fuel injection pump nut, sealing washers and the high-pressure fuel
injection pump supply tube.
Installation
1. NOTE:
NOTE:
Install the new sealing washers and high-pressure fuel injection pump supply tube and nut to the high-pressure fuel injection pump.
2. Install the high-pressure fuel injection pump supply tube bracket nuts.
3. NOTICE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Fuel Injection Pump Supply Tube — Body Off .................................................................................................................. 303-04C-2
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fuel Injection Pump Supply Tube — Body Off

Special Tool(s)
Caps, Fuel System

310-158
Material
Item Specification
Item Part Number Description cardiagn.com

NOTE:
LH turbocharger inlet pipe removed from art for clarity.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

Turbocharger Oil Feed Tube
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1 8287 Air cleaner outlet pipe hose clamp
2 6N664 Air cleaner outlet pipe hose
3 6K786 Air cleaner outlet pipe clamp
4 6K646 Air cleaner outlet pipe
5 W300005 Turbocharger oil feed tube bolt
6 W302472 Turbocharger oil feed tube banjo bolts (2 required)
7 W302474 Turbocharger oil feed tube copper sealing washer (2 required) (not
shown)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

7 W303659 Turbocharger oil feed tube Viton® sealing washer (4 required)
(shown in art)
8 W302203 Turbocharger oil feed tube O-ring seal
9 9T516 Turbocharger oil feed tube
10 W301643 Turbocharger heat shield bolts (5 required)
11 9F460 Turbocharger heat shield
Fuel Injection Pump Supply Tube
NOTE:
Turbocharger removed from art for clarity.
cardiagn.com

9F759)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

pump nut
pump copper sealing washer (shown in art)
pump Viton® sealing washer (2 required) (not shown)
Removal
NOTE:
It is recommended that this component be serviced with the vehicle body removed. If the body cannot be removed, refer to Fuel Injection Pump Supply Tube
— Body On in this section.
1. Shut the engine off and wait 5 minutes, to allow the fuel in the fuel filter module to partially drain.
2. NOTICE:
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Remove the cover and, using a suitable suction device, remove the fuel from the fuel filter module.
• Install the cover when finished.
3. Remove the vehicle body. For additional information, refer to Section 502-02.
4. Loosen the exhaust downpipe-to-turbocharger clamp.
5. Remove the 2 exhaust downpipe-to-Oxidation Catalytic Converter (OC) bolts and remove the exhaust downpipe from the vehicle.
• Discard the clamp and gasket.
6. Disconnect the Exhaust Gas Recirculation Temperature (EGRT) sensor electrical connector.
7. Disconnect the Exhaust Pressure (EP) sensor tube fitting.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
8. Remove the EGR-OC pipe bracket-to-cylinder head bracket bolt and washer. Remove the cylinder head bracket-to-cylinder head bolt, washers and the
bracket.
• Discard the bolts.
9. NOTICE:
Do not bend or twist the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe or damage to the bellows on the EGR-
OC pipe may occur.
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Remove the 2 RH turbocharger inlet pipe-to-EGR-OC pipe bolts.
10. Remove the 2 EGR-OC-to-turbocharger bracket bolts.

11. Remove the 2 EGR-OC-to-EGR cooler bolts.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
12. Remove the EGR-OC pipe from the vehicle.

• Discard the gaskets.
13. NOTICE:
Do not bend or twist the turbocharger inlet pipe or damage to the bellows on the turbocharger inlet pipe may occur.
Remove the 3 RH turbocharger inlet pipe-to-turbocharger bolts.
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14. Remove the 3 RH turbocharger inlet pipe-to-exhaust manifold nuts.

• Discard the nuts.
15. Remove the RH turbocharger inlet pipe from the vehicle.

16. Inspect the EGR-OC pipe for damage, obstructions or plugging of the filter. If the filter cannot be cleaned or the obstruction removed, install a new
EGR-OC pipe.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
22. Remove the clamp and disconnect the air cleaner outlet pipe hose.
23. Loosen the clamp and remove the air cleaner outlet pipe.
24. NOTE:
Use a back-up wrench to prevent the fittings from turning.
Remove the 2 turbocharger oil feed tube banjo bolts and the sealing washers.
25. Remove the bolt and the turbocharger oil feed tube.
• Remove and discard the O-ring seal.
26. Remove the 5 bolts and the turbocharger heat shield.
27. Loosen the 2 high-pressure fuel injection pump supply tube bracket nuts.
28. NOTICE:
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NOTE:
NOTE:
Remove the high-pressure fuel injection pump supply tube-to-high-pressure fuel injection pump nut and the sealing washers, and detach the high-
pressure fuel injection pump supply tube.
29. NOTE:
Use a commercially available disconnect tool and a screw driver to release the fuel tube.
Disconnect the fuel injection pump supply tube from the fuel filter module. Remove the fuel injection pump supply tube.
Installation
1. NOTE:
When installing the high-pressure fuel injection pump supply tube make sure the tube is under the retaining nuts at the turbocharger.
NOTE:
There will be a click sound when the tube is correctly installed.
Position the fuel injection pump supply tube and connect it to the fuel filter module.
2. NOTE:
NOTE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Install new sealing washers, the fuel injection pump supply tube and the nut to the high-pressure fuel injection pump.
3. Tighten the 2 high-pressure fuel injection pump supply tube bracket nuts.
4. Install the turbocharger heat shield and the 5 bolts.
5. NOTE:
Install a new O-ring seal and apply clean engine oil.
Install the turbocharger oil feed tube and the bolt.

6. NOTICE:
correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the turbochargers.
NOTE:
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Use a backup wrench to prevent the fittings from turning.
Install new sealing washers and the 2 banjo bolts on the turbocharger oil feed fittings.
• Verify that the turbocharger oil supply tube does not contact the turbocharger actuator linkage.
7. Position the air cleaner outlet pipe and tighten the clamp.
8. NOTE:
Install a new clamp prior to connecting the hose.
Connect the air cleaner outlet pipe hose and tighten the clamp.
10. Install the LH high-pressure fuel injection pump heat shield, the fuel tube bracket and the 3 nuts.
11. Install the RH high-pressure fuel injection pump heat shield, position the engine-to-body ground wire and install the 2 nuts.
12. Install the 3 RH high-pressure fuel injection pump heat shield bolts.
13. Install the glow plug module heat shield and 3 new pushnuts.
14. Install a new gasket on the RH exhaust manifold-to-turbocharger inlet pipe joint.
15. NOTICE:
Position the RH turbocharger inlet pipe, new turbocharger inlet pipe-to-turbocharger gasket and loosely install 3 new turbocharger inlet pipe-to-
turbocharger bolts.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
16. Loosely install the 3 new turbocharger inlet pipe-to-exhaust manifold nuts.
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17. NOTE:
Engine removed for clarity.
Tighten the 3 RH turbocharger inlet pipe-to-turbocharger bolts and 3 RH turbocharger inlet pipe-to-exhaust manifold nuts.
1 Tighten the bolts to 24 Nm (18 lb-ft).
2 Tighten the nuts to 31 Nm (23 lb-ft).
18. NOTICE:
OC pipe may occur.
NOTICE:
Make sure the correct bolts are installed in the bracket or damage to the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter
(OC) pipe may occur.
NOTE:
EGR-OC pipe-to-RH turbocharger inlet pipe joint shown, EGR-OC pipe-to-horizontal EGR cooler joint similar.
Position the EGR-OC pipe and loosely install new 2 EGR-OC-to-bracket bolts. Install new gaskets and loosely install the 2 new RH inlet pipe-to-
EGR-OC pipe bolts and the 2 new EGR-OC-to-horizontal EGR cooler bolts.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
19. Position the cylinder head bracket and install the EGR-OC bracket-to-cylinder head bracket washer and a new bolt. Loosely install the cylinder head
bracket-to-cylinder head washers and a new bolt. Finger tighten both bolts.
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20. Tighten the 2 EGR-OC-to-EGR cooler bolts.
21. Tighten the 2 RH turbocharger inlet pipe-to-EGR-OC bolts.

22. Tighten the 2 EGR-OC-to-turbocharger bracket bolts.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
23. NOTICE:
Failure to install and correctly tighten the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe bracket bolt will
result in damage to the horizontal EGR cooler and possible engine damage.
Tighten the EGR-OC bracket-to-cylinder head bracket bolt.

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24. NOTICE:
Tighten the cylinder head bracket-to-cylinder head bolt.

25. Install the EP sensor tube fitting.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
26. Connect the EGRT sensor electrical connector.
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27. NOTE:
Do not install the exhaust downpipe until the RH turbocharger inlet pipe and the EGR-OC pipe are installed and all fasteners are tightened.
Position the exhaust downpipe into the vehicle and loosely install the 2 exhaust downpipe-to-OC bolts.
28. Install a new exhaust downpipe-to-turbocharger gasket.
29. Position the exhaust downpipe to the turbocharger and install and pre-tighten a new exhaust downpipe-to-turbocharger clamp.
• Make sure the exhaust downpipe clip is over the lip on the turbocharger.
▪ Align the new exhaust downpipe-to-turbocharger clamp so that the exhaust downpipe clip and the opening in the exhaust downpipe-to-
turbocharger clamp are aligned and tightened to maintain position.
▪ Align the downpipe so that the area just above the flat in the pipe is approximately 20 mm (0.787 in) from the frame.
• Pre-tighten to 10 Nm (89 lb-in) to stiffen the joint.
30. Tighten the 2 exhaust downpipe-to-OC bolts.
31. Tighten the exhaust downpipe-to-turbocharger clamp.
32. Install the vehicle body. For additional information, refer to Section 502-02.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Fuel Injection Pump to Fuel Cooler Return Tube — Body Off .......................................................................................... 303-04C-2
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fuel Injection Pump to Fuel Cooler Return Tube — Body Off

Special Tool(s)
Caps, Fuel System

310-158
NOTE:
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

Fuel Injection Pump-to-Fuel Cooler Return Tube
NOTE:
cardiagn.com
1 — Fuel injector return tube fitting (part of 96273)
2 W302473 Fuel injection pump-to-fuel cooler return tube nut
3 W302474 Fuel injection pump-to-fuel cooler return tube copper sealing washer
(shown in art)
3 W303659 Fuel injection pump-to-fuel cooler return tube Viton® sealing
washer (2 required) (not shown)
4 9B337 Fuel injection pump-to-fuel cooler return tube
Removal
NOTE:
It is recommended that this component be serviced with the vehicle body removed. If the body cannot be removed, refer to Fuel Injection Pump to Fuel
Cooler Return Tube — Body On in this section.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
cardiagn.com
bracket.
7. NOTICE:
OC pipe may occur.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

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11. NOTICE:

2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

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EGR-OC pipe.
18. NOTICE:
Disconnect the fuel injector return tube fitting at the check valve.
19. NOTICE:
NOTE:
NOTE:
Remove the nut, the sealing washers and the fuel injection pump-to-fuel cooler return tube.
Installation
1. NOTE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
NOTE:
NOTE:
Install new sealing washers, the fuel injection pump-to-fuel cooler return tube and the nut to the high-pressure fuel injection pump.
• For Viton® sealing washers, using a torque adapter, tighten to 25 Nm (18 lb-ft).
• For copper sealing washer, using a torque adapter, tighten to 38 Nm (28 lb-ft).
2. NOTE:
Connect the fuel injector return tube fitting at the check valve.
3. Install the LH high-pressure fuel injection pump heat shield, the fuel tube bracket and the 3 nuts.
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4. Install the RH high-pressure fuel injection pump heat shield, position the engine-to-body ground wire and install the 2 nuts.
5. Install the 3 RH high-pressure fuel injection pump heat shield bolts.
6. Install a new gasket on the RH exhaust manifold-to-turbocharger inlet pipe joint.
7. NOTICE:
Position the RH turbocharger inlet pipe, new turbocharger inlet pipe-to-turbocharger gasket and loosely install the 3 new turbocharger inlet pipe-to-
turbocharger bolts.
9. NOTE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Engine removed for clarity.
10. NOTICE:
cardiagn.com
OC pipe may occur.
NOTICE:
Make sure the correct bolts are installed in the bracket or damage to the exhaust gas recirculation (EGR)-Oxidation Catalytic Converter
NOTE:
Position the EGR-OC pipe and loosely install 2 new EGR-OC-to-bracket bolts. Install new gaskets and loosely install the 2 new RH inlet pipe-to-
bracket-to-cylinder head washers and a new bolt. Finger-tighten both bolts.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

cardiagn.com
15. NOTICE:

2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
16. NOTICE:

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2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
19. NOTE:
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Fuel Injection Pump to Fuel Cooler Return Tube — Body On .......................................................................................... 303-04C-2
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fuel Injection Pump to Fuel Cooler Return Tube — Body On

Special Tool(s)
Caps, Fuel System

310-158
cardiagn.com

2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

Fuel Injection Pump-to-Fuel Cooler Return Tube
cardiagn.com
1 — Fuel injector return tube fitting (part of 96273)
2 W302473 Fuel injection pump-to-fuel cooler return tube nut
3 W302474 Fuel injection pump-to-fuel cooler return tube copper sealing washer
(shown in art)
3 W303659 Fuel injection pump-to-fuel cooler return tube Viton® sealing
washer (2 required) (not shown)
4 9B337 Fuel injection pump-to-fuel cooler return tube
Removal
NOTE:
It is recommended that this component be serviced with the vehicle body removed. If the body can be removed, refer to Fuel Injection Pump to Fuel Cooler
Return Tube — Body Off in this section.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
wire.
5. NOTICE:
cardiagn.com
6. NOTICE:
NOTE:
NOTE:
Remove the nut, sealing washers and fuel injection pump-to-fuel cooler return tube.
Installation
1. NOTE:
NOTE:
Install the fuel injection pump-to-fuel cooler return tube, new sealing washers and nut.
2. NOTE:
3. NOTICE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Fuel Cooler to Fuel Filter Module Return Tube ................................................................................................................ 303-04C-2
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fuel Cooler to Fuel Filter Module Return Tube

Special Tool(s)
Caps, Fuel System

310-158
Charge Air Cooler (CAC) Tube Flex Coupling
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Fuel Cooler-to-Fuel Filter Module Return Tube
cardiagn.com
2 W302472 Fuel cooler-to-fuel filter module return tube banjo bolt
3 W302474 Fuel cooler-to-fuel filter module return tube copper sealing washer
(shown in art)
3 W303659 Fuel cooler-to-fuel filter module return tube Viton® sealing washer
(2 required) (not shown)
4 W303659 Fuel cooler-to-fuel filter module Viton® sealing washers (2
required)
5 W302472 Fuel cooler-to-fuel filter module return tube banjo bolt
6 9N104 Fuel cooler-to-fuel filter module return tube
Removal
1. Shut the engine off and wait 5 minutes, to allow the fuel in the fuel filter module to partially drain.
2. NOTICE:
4. NOTICE:
Remove the 2 banjo bolts, the sealing washers, sealing washers and the fuel cooler-to-fuel filter module return tube.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Installation
1. NOTICE:
Only use banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the
Position the fuel cooler-to-fuel filter module return tube. Install new sealing washers and the banjo bolt to the fuel filter module.
2. NOTICE:
Install 2 new sealing washers and the fuel cooler-to-fuel filter module banjo bolt to the fuel cooler.
3. Install the flexible section of the CAC tube and tighten the clamps.
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4. Bleed the low-pressure fuel system. For additional information, refer to Section 310-00.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Fuel Injector Return Tube — Body Off .............................................................................................................................. 303-04C-2
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fuel Injector Return Tube — Body Off

Special Tool(s)
Caps, Fuel System

310-158
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Throttle Body (TB) and Front End Accessory Drive (FEAD)
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1 — EGR valve electrical connector (part of 12A581)
2 — Throttle Body (TB) electrical connector (part of 12A581)
3 W300014 TB adapter bolts (2 required)
4 W302554 TB adapter bolts (2 required)
5 9F452 TB and TB adapter assembly
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

6 9P457 TB adapter gasket
7 W705831 Front End Accessory Drive (FEAD) bracket nuts (2 required)
8 W709986 FEAD bracket bolts (2 required)
9 10039 FEAD bracket
10 W700839 Power steering pump bolts (3 required)
11 3A696 Power steering pump
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Wiring Harness and Heater Core Supply Tube
cardiagn.com

1 — High-pressure fuel pump electrical connector (part of 9F759)
4 W300049 Heater supply tube nut
5 W300005 Heater supply tube bolt
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

6 — Heater supply tube
7 W302448 Heater supply tube O-ring seal
9 — Fuel temperature sensor electrical connector (part of 12A581)
Fuel Filter Module and Thermostat Housing
cardiagn.com
1 W302477 Fuel filter module stud bolt
2 W300015 Fuel filter module bolts (2 required)
3 — Fuel filter module
4 W301558 Fuel filter module supply tube banjo bolt (M14)
5 W302475 Fuel filter module supply tube copper sealing washer (shown in art)
5 W303692 Fuel filter module supply tube Viton® sealing washer (2 required)
(not shown)
6 9B273 Fuel filter module supply tube
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

7 W302472 Fuel filter module return tube banjo bolt (M12)
8 W302474 Fuel filter module return tube copper sealing washer (shown in art)
8 W303659 Fuel filter module return tube Viton® sealing washer (2 required)
(not shown)
9 9C273 Fuel filter module return tube
10 W300014 Thermostat housing collar bolts (4 required)
11 — Thermostat housing collar
12 — Thermostat housing
13 8255 Thermostat housing gasket
Fuel Injector Return Tube
cardiagn.com

1 W302472 Fuel injector return tube banjo bolts (2 required)
2 W302474 Fuel injector return tube copper sealing washers (2 required) (shown
in art)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

2 W303659 Fuel injector return tube Viton® sealing washers (4 required) (not
shown)
3 W300002 Fuel injector return tube bracket bolts (2 required)
4 W300004 Fuel injector return tube bracket nut
6 9C273 Fuel injector return tube
Removal
NOTE:
It is recommended that this component be serviced with the vehicle body removed. If the body cannot be removed, refer to Fuel Injector Return Tube —
Body On in this section.
1. Remove the turbocharger. Carry out the Turbocharger — Body Off procedure. For additional information, refer to Section 303-04D.
2. Remove the A/C compressor drive belt. For additional information, refer to Section 303-05.
3. Remove the EGR vertical cooler. For additional information, refer to Section 303-08.
cardiagn.com
5. NOTICE:
6. NOTE:
To aid in repositioning the power steering pump, raise the supply tube up to clear the Engine Coolant Temperature (ECT) sensor connector.
Remove the 3 bolts and position the power steering pump aside.
7. Remove the 2 nuts and the 2 bolts and position the Front End Accessory Drive (FEAD) bracket forward.
8. Disconnect the EGR valve and Throttle Body (TB) electrical connectors.
9. Remove the 4 bolts and the TB and TB adapter assembly.
• Remove and discard the press-in-place gasket.
10. Disconnect the fuel temperature sensor electrical connector and detach the wiring harness retainer.
11. Remove the bolt and disconnect the engine wiring harness.
13. Remove the bolt and position the engine wiring harness aside.
14. NOTICE:
Do not bend or flex the heater supply tube or damage to the tube may occur.
Remove the nut, the bolt and the heater supply tube.
15. NOTICE:
16. NOTICE:
Remove the fuel supply and return tube banjo bolts and sealing washers from the fuel filter module.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
17. NOTICE:
Remove the 2 bolts, the stud bolt and the fuel filter module. Position the fuel filter module to the passenger side of the vehicle.
18. Remove the 4 bolts, the collar and the thermostat housing.
19. Remove the fuel injector return tube bracket nut.
20. Remove the 2 fuel injector return tube bracket bolts.
21. NOTICE:
Remove the 2 banjo bolts, the sealing washers and the fuel injector return tube.
Installation
1. NOTICE:
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Position the fuel injector return tube. Install new sealing washers and the 2 banjo bolts to the cylinder heads.
2. Install the 2 fuel injector return tube bracket bolts.
3. Install the fuel injector return tube bracket nut.
4. Install a new press-in-place gasket, the thermostat housing, the thermostat housing collar and the 4 bolts.
5. Position the fuel filter module and install the 2 bolts and stud bolt.
6. NOTICE:
Install new sealing washers, position the fuel supply and return tubes to the fuel filter module and install the 2 banjo bolts.
• For M14 banjo bolt with Viton® sealing washers, tighten to 28 Nm (21 lb-ft).
• For M14 banjo bolt with copper sealing washer, tighten to 47 Nm (35 lb-ft).
7. NOTICE:
NOTE:
Install a new O-ring seal.
Install the heater supply tube, the bolt and the nut.
8. Position the engine wiring harness on the engine and install the bolt.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
10. Position the engine wiring harness and install the bolt.
11. Connect the fuel temperature sensor electrical connector and attach the retainer.
12. Install a new press-in place gasket, the TB and TB adapter assembly and the 4 bolts.
13. Connect the EGR valve and TB electrical connectors.
14. Position the FEAD bracket and install the 2 nuts and 2 bolts.
15. NOTE:
Raise the supply tube up to clear the ECT sensor connector when repositioning the power steering pump.
NOTE:
Make sure the power steering pressure tube retainer is on the retaining stud prior to tightening the bolts for the power steering pump.
Position the power steering pump and install the 3 bolts. Secure the hose on the engine.
16. NOTE:
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17. Position the glow plug module heat shield and install 3 new pushnuts.
18. Install the EGR vertical cooler. For additional information, refer to Section 303-08.
19. Install the A/C compressor drive belt. For additional information, refer to Section 303-05.
20. Install the turbocharger. Carry out the Turbocharger — Body Off procedure. For additional information, refer to Section 303-04D.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Fuel Injector Return Tube Check Valve ........................................................................................................................... 303-04C-2
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fuel Injector Return Tube Check Valve

Removal and Installation
1. The fuel injector return tube check valve is an integral part of the fuel injection pump-to-fuel cooler return tube, and must be serviced with the tube.
For additional information, refer to Fuel Injection Pump to Fuel Cooler Return Tube — Body On or Fuel Injection Pump to Fuel Cooler Return Tube
— Body Off in this section.
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Fuel Injector Return Tube — Body On .............................................................................................................................. 303-04C-2
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fuel Injector Return Tube — Body On

Special Tool(s)
Caps, Fuel System

310-158
Fuel Injector Return Tube
NOTE:
Engine front cover removed for clarity.
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

1 W302472 Fuel injector return tube banjo bolts (2 required)
2 W302474 Fuel injector return tube copper sealing washers (2 required) (shown
in art)
2 W303659 Fuel injector return tube Viton® sealing washers (4 required) (not
shown)
3 W300002 Fuel injector return tube bracket bolts (2 required)
4 W300004 Fuel injector return tube bracket nut
5 — Fuel injector return tube fitting
6 9C273 Fuel injector return tube
Removal
NOTE:
It is recommended that this component be serviced with the vehicle body removed. If the body can be removed, refer to Fuel Injector Return Tube — Body
Off in this section.
2. Remove the cooling fan stator. For additional information, refer to Section 303-03.
cardiagn.com
3. Remove the accessory drive belt.
4. If equipped, remove the A/C drive belt.

• Remove the belt from the bottom of the A/C clutch pulley, then remove it from the crankshaft pulley.
5. Disconnect the crankcase vent oil separator tube.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
6. Remove the 4 bolts and the crankcase vent oil separator.

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7. Disconnect the heater hose from the heater supply tube.
8. Remove the 3 pushnuts and the glow plug heat shield.

9. NOTICE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
10. Disconnect the high-pressure fuel injection pump electrical connector. Disconnect the pin-type retainer from the glow plug bracket.
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11. Remove the retaining nut for the power steering hoses.
12. NOTE:
Raise the supply tube up to clear the Engine Coolant Temperature (ECT) sensor connector when positioning the power steering pump aside.
Remove the 3 bolts and position aside the power steering pump.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
13. NOTE:
The Front End Accessory Drive (FEAD) is not removed, it is positioned forward to access the front banjo bolt.
NOTE:
It may be necessary to position the accessory drive tensioner to access the lower bolt. Remove the bottom bolt first.
Remove the 2 nuts and the 2 bolts and position the FEAD bracket forward.
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14. Remove the bolt and the EGR cooler coolant tube.
15. NOTICE:
The coolant hose clamps used on this engine are constant tension worm gear clamps. Standard worm gear clamps cannot be used. Failure to
use the correct coolant hose clamps may result in hose joint failure.
Loosen the clamp and disconnect the EGR cooler hose.

• Discard the EGR cooler clamp.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
16. Remove the 2 retaining nuts for the vertical EGR cooler.
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17. Disconnect the hose and retaining clips at the vertical EGR cooler. Disconnect the Exhaust Gas Recirculation Temperature (EGRT) sensor electrical
connector.
18. Remove the nut and retaining clip.
19. Remove the nut and bolt for the vertical EGR cooler.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
20. Remove the vertical EGR cooler stud.

• Remove and discard the gasket.
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21. Remove the 5 bolts and the vertical EGR cooler assembly.
• Remove and discard the gasket.
22. Disconnect the Throttle Body (TB) electrical connector.
23. Remove the 4 bolts and the TB adapter.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
24. Disconnect the Intake Air Temperature 2 (IAT2) and Manifold Absolute Pressure (MAP) sensor electrical connectors. Disconnect the RH fuel
charging harness electrical connector and wire retainer.
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25. Disconnect the fuel temperature sensor electrical connector and detach the retainer from the stud.
26. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector and wire retainer.
27. Disconnect the Engine Oil Temperature (EOT) and Engine Oil Pressure (EOP) sensor electrical connectors.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
28. Disconnect the LH fuel charging harness electrical connector and pin-type retainer.
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29. Remove the bolt and position the engine wiring harness aside.
30. NOTICE:
Remove the nut, the bolt and the RH heater supply tube.
31. NOTICE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Remove the fuel filter supply and return tube banjo bolts and sealing washers from the fuel filter module.
32. Remove the 2 bolts, the stud bolt and the fuel filter module.
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33. Remove the 4 bolts, the collar and the thermostat housing.
34. Remove the fuel injector return tube bracket nut.

35. Remove the 2 fuel injector return tube bracket bolts.
36. NOTICE:
Remove the 2 banjo bolts, sealing washers and the fuel injector return tube.
Installation
1. NOTICE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Position the fuel injector return tube. Install new sealing washers and the 2 banjo bolts to the cylinder heads.
2. Install the 2 fuel injector return tube bracket bolts.
3. Install the fuel injector return tube bracket nut.
4. Install a new press-in-place gasket, the thermostat housing, the collar and the 4 bolts.
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5. Position the fuel filter module and install the 2 bolts and stud bolt.
6. NOTICE:
Install new sealing washers, position the fuel supply and return tubes to the fuel filter module and install the 2 banjo bolts.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
7. NOTICE:
NOTE:
Position the heater supply tube. Install the nut and bolt.
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8. Position the engine wiring harness and install the bolt.

9. Connect the LH fuel charging harness electrical connector and pin-type retainer.
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(Continued)
10. Connect the EOT and EOP sensor electrical connectors.
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11. Connect the ECT sensor electrical connector and wire retainer.
12. Connect the fuel temperature sensor electrical connector and attach the retainer to the stud.
13. Connect the IAT2 and MAP electrical connectors. Connect the RH fuel charging harness electrical connector and the wiring to the heater supply tube.
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(Continued)
14. Install a new press-in-place gasket, TB adapter and loosely install the 4 bolts.
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15. Connect the TB body electrical connector.
16. NOTE:
Install a new horizontal EGR cooler gasket prior to installing the vertical EGR cooler.
Position the vertical EGR cooler assembly and loosely install the 5 bolts.
17. Install a new vertical EGR cooler gasket and install the stud.
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(Continued)
18. Install the nut and bolt for the vertical EGR cooler.
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19. Install the retaining clip and nut on the stud.
20. Connect the EGRT sensor electrical connector. Connect the EGR cooler hose and the retaining clips.
21. NOTICE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Do not bend or twist the exhaust gas recirculation (EGR) cooler bellows or damage to the EGR cooler may occur.
NOTE:
Inspect the corrugation of the vertical EGR cooler inlet to make sure that the corrugation ribs are not touching and are not damaged.
Install the 2 nuts for the vertical EGR cooler.

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22. NOTICE:
The coolant hose clamps used on this engine are constant tension worm gear clamps. Standard worm gear clamps cannot be used. Failure to
use the correct coolant hose clamps may result in hose joint failure.
NOTE:
Install a new clamp on the EGR cooler hose.
Connect the EGR cooler hose and tighten the clamp.

23. Tighten the 5 vertical EGR cooler mounting bolts.

• Tighten the M8 bolts to 31 Nm (23 lb-ft).
• Tighten the M10 bolt to 62 Nm (46 lb-ft).
24. Tighten the 4 bolts for the TB adapter.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
25. NOTE:
Install the EGR cooler coolant tube and bolt.

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26. NOTE:
It may be necessary to position the tensioner to install the lower bolt. Install the lower bolt last.
Position back the FEAD bracket and install the 2 nuts and 2 bolts.
27. Position back the power steering pump and install the 3 bolts.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
28. Install the retaining nut for the power steering hoses.
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29. Connect the high-pressure fuel injection pump electrical connector and pin-type retainer.
30. NOTE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
31. NOTE:
Use a socket to aid in installing the pushnuts.
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32. Connect the heater hose to the heater supply tube.
33. Install a new press-in-place gasket, the crankcase vent oil separator and 4 bolts.
34. Connect the crankcase vent oil separator hose.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
35. If equipped, install the A/C belt.
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36. Install the accessory drive belt.
37. Install the cooling fan stator. For additional information, refer to Section 303-03.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Fuel Injector Supply Tube ................................................................................................................................................ 303-04C-2
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fuel Injector Supply Tube

1. When installing a new fuel injector supply tube, the fuel injector must be removed and a new O-ring seal and sealing washer installed on it.
Additionally, whenever a fuel injector supply tube fitting is loosened, a new fuel injector supply tube must be installed. Therefore, the steps required
to remove and install a fuel injector supply tube are included in the fuel injector procedure. For additional information, refer to Fuel Injectors in this
section.
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2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Fuel Rail ........................................................................................................................................................................... 303-04C-2
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fuel Rail
Material
Item Specification
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1 9D930 LH fuel charging wiring harness
2 W300006 Fuel rail bolts
3 1832761 LH fuel rail
4 9D930 RH fuel charging wiring harness
5 1855643 RH fuel rail
Removal
1. Remove the fuel rail supply tube. For additional information, refer to Fuel Rail Supply Tube — Body Off or Fuel Rail Supply Tube — Body On in
this section.
2. Remove the fuel injectors. For additional information, refer to Fuel Injectors in this section.
3. Detach the fuel charging wiring harness from the fuel rail.
4. Remove the 2 bolts and the fuel rail.
Installation
1. NOTE:
Lubricate the fuel injector O-ring seal with clean engine oil.
Install a new O-ring seal and a soft steel combustion gasket on the fuel injector.
2. NOTICE:
Failure to tighten the fuel injector correctly may lead to engine failure.
NOTICE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
To prevent engine damage, do not use air tools to install the fuel injector. The fuel injector hold-down clamp assembly bolt retainer that
extracts the injector may dislodge and fall into the oil drain hole.
NOTICE:
If the fuel injector hold-down clamp assembly bolt retainer is damaged or missing, a new fuel injector hold-down clamp assembly must be
installed, or the clamp assembly will not be able to remove the fuel injector.
Install the fuel injectors, the fuel injector hold-down clamps and the bolts.
3. Install the fuel rail and the 2 bolts.
• Tighten hand-tight.
4. NOTE:
NOTE:
Use a crowfoot wrench to aid in tightening the fuel injector supply tube.
Install the new fuel injector supply tubes in the following sequence.
1 Remove the Fuel System Caps from the fuel rail and fuel injectors one at a time prior to assembly of each tube.
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2 Position the new fuel injector supply tubes (one at a time) between the fuel rail and the fuel injector and fully hand start and seat the fuel injector
supply tube fittings onto the fuel rail and fuel injector connectors. Snug the fuel injector supply tube fittings using the inside-out step sequence
(the 2 inside tubes then the 2 outside tubes).
3 Tighten the fuel injector hold-down clamp bolt.
4 Tighten the fuel rail bolts.
5 NOTE:
Pre-tighten the fuel injector fittings first, then the fuel rail fittings.
Pre-tighten the fuel injector supply tube fittings.

6 NOTE:
Place a visible mark with a permanent marker on the fuel rail and fuel injector threaded connection. Turning the tube fittings one flat of the fitting
is equal to 60 degrees.
Final-tighten the fuel injector supply tube fittings.

▪ Tighten the tube fittings 60 degrees.
5. Attach the fuel charging wiring harness to the fuel rail.
6. Connect the fuel injector and, if disconnected, the Fuel Rail Pressure (FRP) sensor electrical connectors.
8. Install the fuel rail supply tube. For additional information, refer to Fuel Rail Supply Tube — Body Off or Fuel Rail Supply Tube — Body On in this
section.
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CONTENTS PAGE
Fuel Rail Supply Tube — Body Off ................................................................................................................................... 303-04C-2
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fuel Rail Supply Tube — Body Off

Special Tool(s)
Caps, Fuel System

310-158
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NOTE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

Fuel Rail Supply Tube
NOTE:
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2 9A332 RH fuel rail supply tube
3 9A332 LH fuel rail supply tube
Removal
Both sides
NOTE:
It is recommended that this component be serviced with the vehicle body removed. If the body cannot be removed, refer to Fuel Rail Supply Tube — Body
On in this section.
1.
WARNING:
the fuel to cool.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
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bracket.
8. NOTICE:
Do not bend or twist the exhaust gas recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe or damage to the bellows on the EGR-OC
pipe may occur.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

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12. NOTICE:

2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

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EGR-OC pipe.
RH side
Both sides
17. Remove the 3 high-pressure fuel injection pump heat shield bolts.
21. NOTICE:
NOTE:
NOTE:
Installation
Both sides
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
1. NOTE:
NOTE:
NOTE:
2 NOTE:
Support the tube while hand snugging the fittings to make sure of correct assembly of the joints.
Position the new fuel rail supply tube between the high-pressure fuel injection pump and high-pressure fuel rail. Fully hand start and seat the tube
fittings onto the high-pressure fuel injection pump and high-pressure fuel rail.
3 Snug the tube fittings.
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4 Pre-tighten the fuel rail supply tube fittings.
5 Install the 2 fuel rail supply tube bracket bolts.
▪ Tighten to 13 Nm (115 lb-in).
6 NOTE:
Place a visible mark with a permanent marker on the fuel rail and high-pressure fuel injection pump threaded connection. Turning the tube
fittings one flat of the nut is equal to 60 degrees.

2. NOTICE:
Failure to install the high-pressure fuel injection pump heat shield may result in engine damage.
Install the LH high-pressure fuel injection pump heat shield, the fuel tube bracket and the 3 nuts.
3. Install the RH high-pressure fuel injection pump heat shield, position the ground wire and install the 2 nuts.
4. Install the 3 high-pressure fuel injection pump heat shield bolts.
RH side
5. NOTE:
Both sides
6. Install new gasket on the RH exhaust manifold-to-turbocharger inlet pipe joint.
7. NOTICE:
Position the RH turbocharger inlet pipe, new turbocharger inlet pipe-to-turbocharger gasket and loosely install 3 new turbocharger inlet pipe-to-
turbocharger bolts.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
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9. NOTE:
Engine removed from vehicle for clarity.
10. NOTICE:
OC pipe may occur.
NOTICE:
Make sure the correct bolts are installed in the bracket or damage to the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter
NOTE:
Position the EGR-OC pipe and loosely install 2 new EGR-OC-to-bracket bolts. Install new gaskets and loosely install the 2 new RH inlet pipe-to-
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
bracket-to-cylinder head washers and a new bolt. Finger-tighten both bolts.
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
15. NOTICE:

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16. NOTICE:


2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
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19. NOTE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Fuel Rail Supply Tube — Body On ................................................................................................................................... 303-04C-2
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fuel Rail Supply Tube — Body On

Special Tool(s)
Caps, Fuel System

310-158
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1 W302674 Glow plug module heat shield pushnuts
2 12A345 Glow plug module heat shield
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Fuel Rail Supply Tube
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2 9A332 RH fuel supply tube
3 9A332 LH fuel supply tube
Removal
All vehicles
NOTE:
It is recommended that this component be serviced with the vehicle body removed. If the body can be removed, refer to Fuel Rail Supply Tube — Body Off
in this section.
1.
WARNING:
Shut the engine off and wait until the engine is cool or 5 minutes, whichever is longer, to allow the high-pressure fuel system to bleed off and the fuel
to cool.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
wire.
RH side
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All vehicles
8. NOTICE:
NOTE:
NOTE:
Installation
All vehicles
1. NOTE:
NOTE:
NOTE:
2 NOTE:
Support the tube while hand snugging the fittings to make sure of correct assembly of the joints.
Position the new fuel rail supply tube between the high-pressure fuel injection pump and the high-pressure fuel rail. Fully hand start and seat the
tube fittings onto the high-pressure fuel injection pump and high-pressure fuel rail.
3 Snug the tube fittings.
4 Pre-tighten the fuel rail supply tube fittings.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
5 NOTE:
Place a visible mark with a permanent marker on the fuel rail and the high-pressure fuel injection pump threaded connection. Turning the tube
fittings one flat of the nut is equal to 60 degrees.

RH side
3. NOTE:
All vehicles
4. NOTICE:
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2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Throttle Body .................................................................................................................................................................... 303-04C-2
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

Throttle Body
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1 6K786 Charge Air Cooler (CAC) tube clamp
2 6F073 CAC tube
3 — Throttle Body (TB) electrical connector (part of 12A571)
4 W302054 TB stud bolt
5 W302552 TB bolts (2 required)
6 9G736 TB
7 9P457 TB gasket

1. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12.
2. Loosen the clamp and disconnect the Charge Air Cooler (CAC) tube.
• To install, tighten to 12 Nm (106 lb-in).
3. Disconnect the Throttle Body (TB) electrical connector.
4. NOTE:
Use a tool such as a Snap-On® FTXL30E, or equivalent, to access the bolts.
Remove the stud bolt, the 2 bolts and the TB.

• To install, tighten to 10 Nm (89 lb-in).
5. To install, reverse the removal procedure.
• Install a new press-in-place gasket.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Fuel Injector Sleeve ......................................................................................................................................................... 303-04C-2
cardiagn.com
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fuel Injector Sleeve

Special Tool(s)
Brush, Fuel Injector Sleeve

303-1257
Installer, Injector Sleeve

303-1263
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Remover, Injector Sleeve
303-1262
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
Multi-Purpose Grease ESB-M1C93-B
XG-4 and/or XL-5
Threadlock 262 WSK-M2G351-A6
TA-26
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
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1 W300009 Heater return tube bolt
2 W300005 Heater return tube bolt
3 — Heater return tube
4 W301924 Heater return tube O-ring seal
5 9N951 Fuel injector sleeves (8 required)
Removal
All cylinders
1. Remove the rocker arm assembly for the cylinder(s) being serviced for a fuel injector sleeve. For additional information, refer to Section 303-01C.
No. 2 cylinder
2. Remove the 2 bolts and the heater core return tube.
All cylinders
3. Fill the lower portion the fuel injector sleeve with grease to prevent any metal from falling into the cylinder.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
4. NOTE:
The fuel injector sleeve is made of stainless steel. Lubrication of the fuel injector sleeve removal tap is necessary. Excessive force will be needed to
get the tap started and damage to the tap can occur without lubrication.
Insert the Injector Sleeve Remover tap and the injector sleeve tap pilot into the cylinder head fuel injector bore. Tighten the injector sleeve tap one and
one-half to 2 turns.
5. Install the Injector Sleeve Remover into the threaded sleeve. Using the Injector Sleeve Remover and Slide Hammer, remove the fuel injector sleeve
from the cylinder head fuel injector bore. Discard the sleeve.
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6. Using the Fuel Injector Sleeve Brush, clean the fuel injector bore of deposits and hardened sealant.
Installation
All cylinders
1. Verify the fuel injector bore is clean and dry.
2. Position the new fuel injector sleeve onto the Injector Sleeve Installer. Apply threadlock or equivalent to the very bottom (smallest diameter) and very
top (largest diameter) flat areas.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
3. NOTICE:
Use care when installing fuel injector sleeves in cylinder Nos. 2 and 4 or damage to the turbocharger crossover may occur.
Using the Injector Sleeve Installer, position the fuel injector sleeve into the cylinder head fuel injector bore. Seat the fuel injector sleeve in the fuel
injector bore, using a rubber mallet. If any sealant gets into the inside of the injector sleeve, it must be cleaned out before it hardens.
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No. 2 cylinder
4. NOTE:
Install the coolant return tube and 2 bolts.

All cylinders
5. NOTE:
Lubricate the fuel injector O-ring seal with clean engine oil.
Install a new O-ring seal and a soft steel combustion washer on the fuel injector.
• Make sure the bead on the soft steel combustion washer is facing the cylinder head.
6. NOTICE:
Failure to tighten the injector correctly may lead to engine failure.
NOTICE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
To prevent engine damage, do not use air tools to install the fuel injectors. The fuel injector hold-down clamp assembly bolt retainer that
extracts the injector may dislodge and fall into the oil drain hole.
NOTE:
The fuel injector hold-down bolt is only pre-tightened in this step. Final tightening will take place in the rocker arm assembly procedure.
Install the fuel injector, the fuel injector hold-down clamp and the bolt.
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7. Install the rocker arm assembly for the cylinder(s) as needed. For additional information, refer to Section 303-01C.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

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303-04C-i Fuel Charging and Controls — 6.

SECTION 303-04C Fuel Charging and Controls — 6.4L Diesel

SPECIFICATIONS .................................................................................................................................................................. 303-04C-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

EGR-OC pipe bracket-to-cylinder head bracket bolt a — — —

EGROC-to-EGR cooler bolts

EGR-OC-to-RH turbocharger inlet pipe bolts

EGR-OC-to- turbocharger bracket bolts

Exhaust downpipe-to-OC bolts

Exhaust Pressure (EP) tube fitting 20 — 177

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Torque Specifications (Continued)

Fuel injector hold-down clamp bolt

Fuel injector supply tube fittings

Fuel rail supply tube bracket bolts 13 — 115

Fuel rail supply tube fittings

Heater core return tube bolts 13 — 115

High-pressure fuel injection pump gear bolt b 77 57 —

Turbocharger inlet pipe-to-exhaust manifold nuts

Turbocharger inlet pipe-to-turbocharger bolts

Turbocharger-to- downpipe clamp

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Torque Specifications (Continued)

a Refer to the procedure in this section.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

SECTION 303-04C Fuel Charging and Controls — 6.4L Diesel

DESCRIPTION AND OPERATION

2008 F-250, 350, 450, 550 Super Duty, 7/2007

DESCRIPTION AND OPERATION

The fuel system components consist of the following:

• Engine fuel filter module

2008 F-250, 350, 450, 550 Super Duty, 7/2007

• Engine system emissions

High-Pressure Fuel System Flow

2008 F-250, 350, 450, 550 Super Duty, 7/2007

High-Pressure Fuel Injection Pump

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Piezo Actuated Fuel Injector

2008 F-250, 350, 450, 550 Super Duty, 7/2007

High-Pressure Fuel Pump Cover and Gasket

2008 F-250, 350, 450, 550 Super Duty, 7/2007

SECTION 303-04C Fuel Charging and Controls — 6.4L Diesel

DIAGNOSIS AND TESTING

2008 F-250, 350, 450, 550 Super Duty, 7/2007

DIAGNOSIS AND TESTING

2008 F-250, 350, 450, 550 Super Duty, 7/2007

SECTION 303-04C Fuel Charging and Controls — 6.4L Diesel

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Caps, Fuel System

Finger tighten the loose fitting(s).

If necessary, tighten the high pressure fitting(s).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

If necessary, tighten the low pressure fitting(s).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

SECTION 303-04C Fuel Charging and Controls — 6.4L Diesel

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Adapter, High-Pressure Pump Test

Install commercially available fittings to the fuel injector return tube.

2. Remove the LH cylinder head fuel passage plug.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

2008 F-250, 350, 450, 550 Super Duty, 7/2007

2008 F-250, 350, 450, 550 Super Duty, 7/2007

2008 F-250, 350, 450, 550 Super Duty, 7/2007