High-Pressure Fuel Pump: Installation
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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.
Rotate the camshaft as necessary until the cam lobe for the high-pressure fuel pump is at BDC.
- Lubricate the high-pressure fuel pump tappet and the high-pressure fuel pump drive unit bore with clean engine oil.
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NOTE: Align the notch on the high-pressure fuel pump tappet and with the groove in the high-pressure fuel pump drive unit bore.
Install the high-pressure fuel pump drive tappet.
- Install a new high-pressure fuel pump O-ring seal and lubricate with clean engine oil
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NOTE: Make sure that new high-pressure fuel pump bolts are installed.
Install the high-pressure fuel pump and loosely install the new high-pressure fuel pump bolts, alternately tighten each high-pressure fuel pump bolt one complete revolution until seated. Tighten the high-pressure fuel pump bolts in the following 2 stages.
Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 55°
- 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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NOTE: Make sure that a new high-pressure fuel tube is installed.
Install the new high-pressure fuel tube, then install the high-pressure fuel tube flare nuts, the high-pressure fuel tube bracket bolt and the high-pressure fuel tube bracket nut 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 in the chart below.
Tighten the high-pressure fuel tube flare nuts in the following 3 stages.
Torque: Stage 1: 62 lb.in (7 Nm) Stage 2: 133 lb.in (15 Nm) Stage 3: 30°
- Tighten the high-pressure fuel tube bracket nut.
Torque: 150 lb.in (17 Nm)
- Tighten the high-pressure fuel tube bracket bolt.
Torque: 89 lb.in (10 Nm)
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- Install the high-pressure fuel pump drive unit noise insulator and install the brake vacuum pump noise insulator. Install the high-pressure fuel pump drive unit noise insulator retainer, install the brake vacuum pump noise insulator retainer and install the wire harness retainer.
- Connect the HO2S electrical connector retainer to the high-pressure fuel pump bracket.
- Connect the high-pressure fuel pump fuel supply hose. Refer to: Quick Release Coupling
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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.
- Connect the high-pressure fuel pump electrical connector.
- Install the engine appearance cover, then install and tighten the engine appearance cover retaining nuts.
Torque: 80 lb.in (9 Nm)
- If equipped, install the strut tower cross brace and the new nuts.
Torque: 41 lb.ft (55 Nm)
- If equipped with strut tower cross brace, position the positive battery cable and attach the wiring harness retainer.
- Connect the negative and positive battery cables. Refer to: Battery Disconnect and Connect .
- Pressurize the fuel system. Refer to: Fuel System Pressure Release .