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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Remove the right front wheel and tire. Refer to: Wheel and Tire
Remove the retainer and position the fender splash shield aside.

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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.

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

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Position back the fender splash shield and install the retainer.

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Install the right front wheel and tire. Refer to: Wheel and Tire
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 and 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. Apply clean engine oil to the new high-pressure fuel pump 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.

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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: : 115 lb.in (13 Nm) Stage 2: Tighten an additional: : 45 deg.

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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 bolts, then tighten the high pressure fuel tube flare nuts and the bracket bolts only finger tight at this stage.

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

Refer to the torque wrench adapter formula in the graphic below

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Torque

: High pressure fuel tube flare nuts, : Stage 1: Tighten to: : 62 lb.in (7 Nm) Stage 2: Tighten to: : 89 lb.in (10 Nm) Stage 3: Tighten an additional: : 38 deg. High-pressure fuel tube bracket bolts, tighten to: : 97 lb.in (11 Nm)

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Install the bracket, then install and tighten the nuts.
Torque

: 97 lb.in (11 Nm)

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Connect the high-pressure fuel pump fuel feed tube spring lock coupling. Refer to: Spring Lock Couplings

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Connect the electrical connector, then attach the wiring harness retainers.

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NOTE: When removing or installing the high-pressure fuel pump insulator, spreading the openings will reduce the risk of damage.

Install the high-pressure fuel pump insulator.

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Connect the high-pressure fuel pump electrical connector.

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Install the exhaust gas recirculation valve. Refer to: Exhaust Gas Recirculation (EGR) Valve
Install the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe
Connect the battery. Refer to: Battery Disconnect and Connect
Pressurize the fuel system. Refer to: Fuel System Pressure Release