High-Pressure Fuel Pump: Installation
- Inspect the high-pressure fuel pump roller 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 roller 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.
- Apply clean engine oil to the high-pressure fuel pump drive unit bore, the drive lobe and the roller tappet. Refer to: Specifications
.
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NOTE: The roller tappet's roller goes down towards the camshaft.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 roller tappet.
- Install a new high-pressure fuel pump O-ring seal, apply clean engine oil to the O-ring seal. Refer to: Specifications
.
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NOTE: Make sure that the mating faces are clean and free of foreign material.
Inspect the mounting plate gasket, clean and replace the mounting plate gasket as needed.
- Install the mounting plate and the new bolts to the high-pressure fuel pump.
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NOTE: Install new high-pressure fuel pump bolts.
Install the high-pressure fuel pump with the mounting plate with the new high-pressure fuel pump bolts. Alternately tighten each bolt 1/2 of a revolution until seated, then tighten in the following 2 stages.
Torque: Stage 1: Tighten to: : 89 lb.in (10 Nm) Stage 2: Tighten an additional: : 60 deg.
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NOTE: Ensure that the alignment pin is properly seated in the mounting plate hole.
Install the bracket, then install and tighten the bolt.
Torque: 97 lb.in (11 Nm)
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NOTE: Make sure that a new high-pressure fuel tube is installed.
- Install the new high-pressure fuel tube and the bracket studbolts, then tighten the high pressure fuel tube flare nuts and the bracket studbolts only finger tight at this stage.
- Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas below.
Torque: High pressure fuel tube flare nuts, : Stage 1: Tighten to: : 71 lb.in (8 Nm) Stage 2: Tighten to: : 89 lb.in (10 Nm) Stage 3: Tighten an additional: : 38 deg. High-pressure fuel tube bracket studbolts, tighten to: : 97 lb.in (11 Nm)
- Connect the electrical connector, then attach the wiring harness retainers.
- Connect the high-pressure fuel pump and the camshaft position sensor electrical connectors.
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NOTE: When 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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- Install the high-pressure fuel pump bracket and the bolts finger tight.
- Tighten the bolts in the sequence shown.
Torque: 97 lb.in (11 Nm)
- Install the lower foam high-pressure fuel pump cover and the retainer.
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- Install the lower plastic high-pressure fuel pump cover and the retainer.
- Position the fuel tube and connect the spring lock coupling. Refer to: Spring Lock Couplings .
- Install the upper plastic and the foam high-pressure fuel pump cover and attach the tabs.
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- Position the wiring harness and attach the retainers.
- Attach the wiring harness retainer to the rear engine lift eye.
- Install the intake manifold. Refer to: Intake Manifold .
- Connect the battery negative cable. Refer to: Battery Disconnect and Connect .
- Pressurize the fuel system. Refer to: Fuel System Pressure Release .