Mercury 5L8Z-9D280-AE Fuel Supply Manifold Assembly

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After removing the fuel rail and injectors from the engine, you need to perform the following steps:a) Remove the clamp that secures each fuel injector to the fuel rail.b) Pull out the fuel injectors from the fuel rail.c) Remove the old O-rings from each injector and discard them.d) Install new O-rings on the injectors before reassembling them and the fuel rail.e) Lubricate the new injector O-rings with clean engine oil before installing them.

To remove the intake manifold on 2008 and later models, depressurize the fuel system, and disconnect the cable from the negative battery terminal. Remove the outlet tube from the air cleaner, remove the front collision impact sensor, transaxle fluid level dipstick. Remove the lower intake manifold mounting bolt that is above the engine oil dipstick tube, then remove the dipstick and tube. Disconnect the wiring from the oil pressure switch and throttle body. Disconnect the power steering tube and the vapor hose. Disconnect the wiring harnesses from the knock sensor, MAP sensor, and the swirl control solenoid and sensor. Loosen the two center intake manifold bolts, remove the five remaining intake manifold bolts. Disconnect the PCV hose and remove the intake manifold. Installation is the reverse of removal, replace the intake manifold gaskets if they are damaged, and tighten the mounting bolts to the torque listed.

To start replacing the fuel injectors, first, relieve the fuel system pressure and equalize tank pressure by removing the fuel filler cap. Then, disconnect the cable from the negative battery terminal and remove the air intake duct. After that, disconnect the accelerator cable and cruise control cable (if equipped) from the throttle lever cam.