High-Pressure Fuel Pump: Installation

Inspect the high-pressure fuel pump tappet. If any flat spots or scoring are found, especially in the indicated areas, then inspect the high-pressure fuel pump and the high-pressure fuel pump tappet drive lobe. Install new components as needed.

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NOTE: Only rotate the crankshaft Clockwise (CW) or damage to the engine may occur.

NOTE: The cam lobe for the high-pressure fuel pump must be at BDC for the high-pressure fuel pump installation.

Using the crankshaft pulley bolt, turn the crankshaft until the high-pressure fuel pump cam lobe is at BDC.

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NOTE: Align the notch on the high-pressure fuel pump tappet with the groove in the high-pressure fuel pump drive unit bore.

Apply clean engine oil to the high-pressure fuel pump drive unit bore and the drive lobe and the high-pressure fuel pump tappet. Install the high-pressure fuel pump tappet.

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Install a new high-pressure fuel pump O-ring seal. Lubricate the new O-ring seal with clean engine oil.

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NOTE: Install new high-pressure fuel pump bolts.

Install the high-pressure fuel pump and the new high-pressure fuel pump bolts. Alternately tighten each bolt 1/2 of a turn until seated and then tighten in the following 2 stages.

Torque:

Stage 1: 44 lb.in (5 Nm)

Stage 2: 55 °

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Install the high-pressure fuel pump bracket, then install and tighten the high-pressure fuel pump bracket bolts.
Torque: 150 lb.in (17 Nm)

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Connect the harness retainers to the high-pressure fuel pump bracket.

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Connect the high-pressure fuel pump fuel feed tube quick release coupling. Refer to: Quick Release Coupling .

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

Install the new high-pressure fuel tube and then tighten the high pressure fuel tube flare nuts only finger tight at this stage.

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Install the high-pressure fuel tube nut and bolt only tighten finger tight at this stage.

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NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas shown below.

Tighten the high pressure fuel tube flare nuts in the following 2 stages.

Torque:

Stage 1: 133 lb.in (15 Nm)

Stage 2: 30 °

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1. Tighten the high-pressure fuel tube nut.
  Torque: 150 lb.in (17 Nm)
2. Tighten the high-pressure fuel tube bolt.
  Torque: 89 lb.in (10 Nm)
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Install the evaporative emission canister purge valve, then install and tighten the evaporative emission canister purge valve bracket nuts.
Torque: 97 lb.in (11 Nm)

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NOTE: When removing or installing the high-pressure fuel pump noise insulator, spreading the openings will reduce the risk of damage.

Install the high-pressure fuel pump noise insulator.

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Connect the high-pressure fuel pump electrical connector.

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Attach the brake vacuum line retainer.

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Install the upper air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
1. NOTE: Lubricating the grommets with silicone grease will aid in the installation of the engine appearance cover, and any future removal and installation of the cover.
  
  Lubricate each grommet with silicone grease.
  
  Material: Motorcraft ® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)
2. Position the engine appearance cover onto engine with the grommets aligned with the studs.
3. Press down on the engine appearance cover at each grommet location to attach the grommets onto the studs.
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Connect the battery. Refer to: Battery Disconnect and Connect .
Pressurize the fuel system. Refer to: Fuel System Pressure Release .