High-Pressure Fuel Pump: Installation

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

NOTE: The drive lobe for the high-pressure fuel pump must be at BDC (bottom dead center) for the high-pressure fuel pump installation.

With the help of an assistant, using the crankshaft pulley bolt, turn the crankshaft until the high-pressure fuel pump drive lobe is at BDC.

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Apply clean engine oil to the high-pressure fuel pump mounting pedestal bore, the drive lobe and the roller tappet. Install the high-pressure fuel pump roller tappet. Refer to: Specifications .

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Inspect the high-pressure fuel pump mounting plate seal and replace as needed. Lubricate the mounting plate seal with clean engine oil. Refer to: Specifications .

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Install a new high-pressure fuel pump O-ring seal. Lubricate with clean engine oil. Refer to: Specifications .

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Inspect the high-pressure fuel pump mounting plate O-ring seals and replace as needed. Lubricate with clean engine oil. Refer to: Specifications .

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NOTE: Make sure that new bolts are installed.

Install the high-pressure fuel pump mounting plate on to the high-pressure fuel pump. Install the new high-pressure fuel pump bolts.

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1. Install the high-pressure fuel pump with the mounting plate and the bolts. Tighten the fuel high-pressure fuel pump bolts in the following 5 stages.
  Torque
  
  :Stage 1: Finger tighten all of the bolts : 0 lb.in (0 Nm) Stage 2: Tighten bolt 1 : 1turn(s) Stage 3: Tighten bolt 2 : 1turn(s) Stage 4: Repeat stages 2 and 3, until reaching : 89 lb.in (10 Nm) Stage 5: Tighten bolts 1 and 2, in sequence an additional : 45 deg.
2. Tighten the high-pressure fuel pump mounting plate bolt.
  Torque: 89 lb.in (10 Nm)
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Attach the hose retainer.

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

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

Install the high-pressure fuel pump to fuel rail high-pressure fuel tube and tighten the flare nuts finger tight.
Install the high-pressure fuel pump to fuel rail high-pressure fuel tube retaining bolts finger tight.
NOTE: In stage 3, if the torque required to tighten any flare nut on the new high-pressure fuel tube reaches or exceeds 55 lb.ft (75 Nm), then that high pressure fuel tube must be discarded and replaced with another new high-pressure fuel tube

Tighten the high-pressure fuel pump to fuel rail high-pressure fuel tube flare nuts.

Torque: Stage 1: 62 lb.in (7 Nm)Stage 2: 89 lb.in (10 Nm)Stage 3: 30 deg.
Tighten the high-pressure fuel pump to fuel rail high-pressure fuel tube retaining bolts.
Torque: Stage 1: 89 lb.in (10 Nm) Stage 2: 45 deg.

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NOTE: The spring lock coupling must be installed onto the fuel tube end along the centerline. The assembly is complete when the tube end bottoms out on the spring lock coupling with an audible click / snap feel. Correct assembly should be verified by pulling back on the spring lock coupling end.
1. Connect the high-pressure fuel pump supply line, then connect the spring lock coupling. Refer to: Spring Lock Couplings .
2. Install the secondary latch.
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Connect the high-pressure fuel pump electrical connector.

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Connect the negative battery cable. Refer to: Battery Disconnect and Connect .
Pressurize the fuel system. Refer to: Fuel System Pressure Release .
Install the engine appearance cover into the rear retainers, then install and tighten the engine appearance cover retainers.
Torque: 97 lb.in (11 Nm)

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