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 drive unit bore, the drive lobe and the roller tappet. Refer to: Specifications .

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NOTE: The roller tappets roller goes down towards the camshaft.

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

Install the high-pressure fuel pump tappet.

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

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Install the high-pressure fuel pump, then install and finger tighten the high-pressure fuel pump nuts. Alternately tighten each of the high-pressure fuel pump nuts one complete revolution until seated. Then tighten the fuel high-pressure fuel pump nuts in the following 2 stages.
Torque: Stage 1: Tighten to : 177 lb.in (20 Nm) Stage 2: Tighten an additional : 45 deg.

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

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

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NOTE: In stage 2, 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.

Install the high-pressure fuel tube and tighten the flare nuts finger tight, then tighten the flare nuts in the following 2 stages.

Torque: Stage 1: Tighten to: : 62 lb.in (7 Nm) Stage 2: Tighten to: : 22 lb.ft (30 Nm)

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Connect the high-pressure fuel pump electrical connector.

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Install the fuel supply manifold, then install and tighten the retainers.
Torque: 89 lb.in (10 Nm)

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Connect the fuel supply quick connect coupling and the spring lock coupling. Attach the wire harness retainers. Refer to: Quick Release Coupling . Refer to: Spring Lock Couplings .

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Connect the quick release couplings. Refer to: Quick Release Coupling .

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Install the high-pressure fuel pump shield, then install and tighten the retainers.
Torque: 89 lb.in (10 Nm)

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Attach the wiring harness retainers.

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Attach the harness retainers.

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Install the intake manifold. Refer to: Intake Manifold .
Reconnect the battery negative cable. Refer to: Battery Disconnect and Connect .
Pressurize the fuel system. Refer to: Fuel System Pressure Release .