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.
- 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.
- Position back the fender splash shield and install the retainer.
- 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.
- 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.
If equipped, inspect the mounting plate gasket, clean and replace the mounting plate gasket as needed.
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NOTE: Install new high-pressure fuel pump bolts.
If equipped, install the mounting plate and the bolts to the high-pressure fuel pump.
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NOTE: Failure to alternately tighten the high pressure pump bolts 1/2 revolution at a time until seated can result in damage to, or failure of the high pressure pump.NOTE: Install new high-pressure fuel pump bolts.
Install the high-pressure fuel pump, if equipped the mounting plate and the new high-pressure fuel pump bolts. Alternately tighten each bolt 1/2 revolution until seated, then tighten in the following 2 stages.
Torque:Stage 1: Tighten to: 10 NmStage 2: Tighten an additional: 60deg.
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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 below.
Torque:High pressure fuel tube flare nuts, : Stage 1: Tighten to: : 7 NmStage 2: Tighten to: : 10 NmStage 3: Tighten an additional: : 38deg.High-pressure fuel tube bracket bolts, tighten to: : 11 Nm
- Install the bracket, then install and tighten the nuts.
Torque: 11 Nm
- Connect the high-pressure fuel pump fuel feed tube spring lock coupling. Refer to: Spring Lock Couplings
.
- 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.
- Connect the high-pressure fuel pump electrical connector.
- 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 .