Fuel Injection Pump: Installation

NOTE: The cam lobe for the fuel injection pump must be at Bottom Dead Center (BDC) for the fuel injection pump installation.

Fig 1: Identifying Position Of Fuel Injection Pump Cam Lobe

Courtesy of FORD MOTOR CO.

Inspect the fuel injection pump tappet. For additional information, refer to FUEL INJECTION PUMP TAPPET INSPECTION .

Fig 2: Inspecting Fuel Injection Pump Tappet
Courtesy of FORD MOTOR CO.
Remove Front Fender Splash Shield.

Fig 3: Remove/Install Front Fender Splash Shield
Courtesy of FORD MOTOR CO.

NOTE: Only rotate the crankshaft clockwise or damage to the engine may occur.

Fig 4: Identifying Crankshaft

Courtesy of FORD MOTOR CO.

NOTE: Apply clean engine oil to the fuel injection pump tappet and to the fuel injection pump cover bore.

Fig 5: Identifying Fuel Injection Pump Tappet

Courtesy of FORD MOTOR CO.

NOTE: Make sure that a new fuel injection pump O-ring seal is installed.

NOTE: Apply clean engine oil to the fuel injection pump O-ring seal.

Fig 6: Identifying Fuel Injection Pump O-Ring Seal

Courtesy of FORD MOTOR CO.

Lubricate and install a new fuel injection pump O-ring seal onto the fuel injection pump.

NOTE: Make sure that new fuel injection pump bolts are installed.

Install the fuel injection pump and loosely install 2 new fuel injection pump bolts, alternately tighten each bolt one complete revolution until seated. Tighten the 2 fuel injection pump bolts in the following 2 stages.
- Stage 1: Tighten each bolt to 5 Nm (44 lb-in).
- Stage 2: Tighten each bolt an additional 55 degrees.
  
  Fig 7: Locating Fuel Injection Pump Bolts
  Courtesy of FORD MOTOR CO.
Tighten to 17 Nm (150 lb-in).

Fig 8: Locating Fuel Injection Pump Side Bolts
Courtesy of FORD MOTOR CO.
Install Front Fender Splash Shield.

Fig 9: Remove/Install Front Fender Splash Shield
Courtesy of FORD MOTOR CO.

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

- Hand tighten the high pressure fuel tube-to-fuel rail flare nut.
- Hand tighten the high pressure fuel tube-to-fuel injection pump flare nut.
  
  Fig 10: Locating High Pressure Fuel Tube-To-Fuel Rail Flare Nuts
  Courtesy of FORD MOTOR CO.
Loosely install the 2 high pressure fuel tube bracket bolts.

Fig 11: Locating High Pressure Fuel Tube Bracket Bolts
Courtesy of FORD MOTOR CO.
Tighten the 2 high pressure fuel tube flare nuts in the following 2 stages.
NOTE: Calculate the correct torque wrench setting for the following torque. Refer to Fig 12 .

Fig 12: Torque Wrench Adapter Formulas
Courtesy of FORD MOTOR CO.
- Stage 1: Using a torque adapter, tighten to 15 Nm (133 lb-in).
- Stage 2: Tighten an additional 30 degrees.
  
  Fig 13: Locating High Pressure Fuel Tube Flare Nuts
  Courtesy of FORD MOTOR CO.
Tighten to 10 Nm (89 lb-in).

Fig 14: Locating High Pressure Fuel Tube Bracket Bolts
Courtesy of FORD MOTOR CO.
For more information, refer to FUEL SYSTEM - GENERAL INFORMATION

Fig 15: Installing High Pressure Fuel Tube
Courtesy of FORD MOTOR CO.

NOTE: Use care when installing the fuel injection pump noise insulator. Spreading the openings will aid in installing the fuel injection pump noise insulator and reduce the risk of damage.

Fig 16: Remove/Install Fuel Injector Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Pressurize the fuel system, For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
Install the ACL outlet pipe, for additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .