Fuel Pump: Installation

Remove the retainers and the cover.

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

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

Rotate the camshaft as needed until the cam lobe for the high-pressure fuel pump is at BDC.

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Lubricate the high-pressure fuel pump tappet and the high-pressure fuel pump drive unit bore with clean engine oil.
Material: Motorcraft® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

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NOTE: Install a new high-pressure fuel pump O-ring seal.

Install the high-pressure fuel pump and loosely install the high-pressure fuel pump bolts, alternately tighten each bolt one half of a revolution until seated. Tighten the high-pressure fuel pump bolts.

Torque: 115 lb.in (13 Nm)

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Install the cover, then install and tighten the cover retainers.
Torque: 27 lb.in (3 Nm)

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NOTE: Only tighten the 2 high-pressure fuel tube flare nuts finger tight at this stage.

NOTE: Make sure that a new component is installed.

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

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Tighten the high-pressure fuel tube flare nuts in the following 3 stages.

Torque: Stage 1: 15 lb.ft (21 Nm) Stage 2: Wait 5min Stage 3: 15 lb.ft (21 Nm)

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NOTE: Make sure that a new component is installed.

Install the new high-pressure fuel pump fuel supply tube and the high-pressure fuel pump fuel supply tube studbolt finger tight.
Tighten install the high-pressure fuel pump fuel supply tube studbolt.
Torque: 62 lb.in (7 Nm)

NOTE: Calculate the correct torque wrench setting for the following torque. Refer to the Torque Wrench Adapter Formulas in the chart below.

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Tighten the high-pressure fuel pump fuel supply tube flare nut in the following 3 stages.

Torque: Stage 1: 15 lb.ft (21 Nm) Stage 2: Wait 5min Stage 3: 15 lb.ft (21 Nm)

Connect the high-pressure fuel pump fuel supply tube. Refer to: Spring Lock Couplings .

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Install the ignition coil-on-plug mounting bracket insulator.

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1. Install the ignition coil-on-plug mounting bracket, then install and tighten the ignition coil-on-plug mounting bracket retainers.
  Torque: Stage 1: 89 lb.in (10 Nm) Stage 2: 53 lb.in (6 Nm)
2. Install the wiring harness, then attach the wiring harness retainers. Connect the FRP sensor electrical connector, the fuel injection pump electrical connector and the CMP electrical connector.
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NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.

Install the high-pressure fuel pump noise insulator.

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1. Install the TC inlet pipe.
2. Install and tighten the TC inlet pipe ball stud and retaining nut.
  Torque: 44 lb.in (5 Nm)
3. Tighten the TC inlet tube clamp.
  Torque: 44 lb.in (5 Nm)
4. Install the crankcase ventilation tube and clamp.
5. Connect the crankcase ventilation tube quick release coupling. Refer to: Quick Release Coupling .
6. Attach the hose retainer.
  Torque: 44 lb.in (5 Nm)
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Install the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
Install the ignition coil-on-plugs. Refer to: Ignition Coil-On-Plug .
Connect the battery. Refer to: Battery Disconnect and Connect .
Pressurize the fuel system. Refer to: Fuel System Pressure Release .