Installation Procedure
- Before continuing, lubricate the cylinder head bore with clean engine oil. Adhesives, Fluids, Lubricants, and Sealers
- NOTE:
- The camshaft MUST be at the base circle position before the fuel pump is installed.
- At the base circle position, the EN-48896 High Pressure Fuel Pump Installation Alignment Gauge will sit flush with the cylinder head.
Install the EN-48896 High Pressure Fuel Pump Installation Alignment Gauge (2) and turn the crankshaft until the camshaft lobe is at the base circle position.
- Remove the EN-48896 High Pressure Fuel Pump Installation Alignment Gauge (1).
Lubricate the NEW fuel pump housing seal (5) with clean engine oil and install it on the fuel pump. Adhesives, Fluids, Lubricants, and Sealers
- ALWAYS make sure the fuel pump bolt retainers are present before installing the fuel pump bolts.
- If ANY fuel pump bolt retainers are missing or NOT suitable for reuse, replace the retainers as necessary.
- The locator tab on the fuel pump bracket gasket should be positioned away from the engine block.
- Install the fuel pump bolts (1) and NEW fuel pump bracket gasket (4) to the fuel pump (2).
- Lubricate the valve lifter follower (3) with clean engine oil and install it into the cylinder head bore. Adhesives, Fluids, Lubricants, and Sealers
- Install the fuel pump assembly (2) into the cylinder head and start the fuel pump bolts (1) by hand.
- Fuel Pump Bolt (1) - Tighten [2x] - Fastener Specifications
Electrical Connector (1) @ Fuel Pump (2) - Connect
- Connect the electrical connector to the fuel pump.
- Ensure ALL fittings are clean and dry prior to assembly.
- NOTE:
Do NOT reuse the fuel feed intermediate pipe. If the fuel feed intermediate pipe fittings are loosened or the pipes are removed, the pipes MUST be replaced.
Fuel Feed Intermediate Pipe (1) - Install NEW
- Slide fuel feed pipe fitting nuts (2) back along fuel feed intermediate pipe (1) to reveal the formed ends (3) of the fuel feed pipe.
- Carefully install the formed ends (3) of the fuel feed intermediate pipe into the sockets of the fuel pump (4) and the fuel injection fuel rails (5).
- Hold the pipe firmly in place and hand tighten the fuel feed pipe fitting nuts (2) onto the threads on the fuel injection fuel rails (5) and the fuel pump (4).
- Fuel Feed Intermediate Pipe Nut (2) @ Fuel Feed Intermediate Pipe (1) - Tighten [3x] - Fastener Specifications
- NOTE:
High pressure fuel feed pipes are one time use only. ALWAYS install a NEW high pressure fuel feed pipe if the pipe is removed OR the fittings are loosened.
Fuel Feed Pipe (1) - Install NEW
- Slide fuel feed pipe fitting (2) back along fuel feed pipe (1) to reveal the formed end (3) of the fuel feed pipe.
- Carefully install the formed end (3) of the fuel feed pipe into the socket of the fuel pump (4).
- Hold the fuel feed pipe firmly in place and hand tighten the fuel feed pipe fitting nut (2) onto the threads of the fuel pump (4).
- Fuel Feed Pipe Fitting (2) @ Fuel Feed Pipe (1) - Tighten - Fastener Specifications
Fuel Feed Pipe Bolt (1) - Install and tighten [2x] - Fastener Specifications
Electrical Connector (1) @ Fuel Feed Pipe Bracket (2) - Install [2x]
Fuel Feed Pipe (1) - Connect - Metal Collar Quick Connect Fitting Service
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
Engine Rear Noise Shield (1) - Install
Fuel Pipe Shield (1) - Install
Wiring Harness (3) - Install
- Retainer (2) - Install [3x]
- Engine Rear Noise Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
Engine Rear Noise Shield Bolt (1) - Install and tighten - Fastener Specifications
Install the plenum front panel (3) to the dash panel upper insulator (2).
- Plenum Panel Nut (1) - Install [9x]
Plenum Front Panel (1) - Install
Plenum Front Panel Bolt (1) - Install and tighten [4x] - Fastener Specifications
- Plenum Front Panel Nut (2) - Install and tighten [3x]
Plenum Front Panel Nut (1) - Install and tighten [3x] - Fastener Specifications
- Plenum Front Panel Bolt (2) - Install and tighten [3x] - Fastener Specifications
- Install the forward lamp wiring harness extension (3) into the plenum front panel.
- Connect the electrical connector.
Air Inlet Deflector Water Deflector (1) - Install
Air Inlet Deflector Water Deflector Retainer (1) - Install [2x]
Install the windshield wiper system module (2) in the vehicle.
- Windshield Wiper System Module Bolt (1) - Install and tighten [2x] Fastener Specifications
- Connect the windshield wiper motor electrical connector.
- Connect the battery negative cable. - Battery Negative Cable Disconnection and Connection
Windshield Wiper System Module Shield (1) - Install
Air Inlet Grille Panel (2) - Install
- Install the air inlet grille panel (2) between both hood hinges.
- Connect the windshield washer nozzle hose to the windshield washer pump hose.
- Air Inlet Grille Panel Retainer (1) - Install [6x]
Front Compartment Side Sight Shield (2) - Install
- Front Compartment Side Sight Shield Retainer (1) - Install [3x]
Air Inlet Grille Panel Extension (2) - Install
- Air Inlet Grille Panel Retainer (1) - Install [2x]
Install the hood rear outer air inlet seal (2) to the left and right side.
- Install the 2 hood rear outer air inlet seal retainer (1) to the left and right side.
Air Inlet Grille Panel Extension (1) - Install [2x]
- Install the air inlet grille panel extension (1).
- Remove the masking tape from the top edge of the service part.
- Using a 50/50 mixture of isopropyl alcohol and clean drinkable water with a clean towel, remove any left over adhesive residue from the masking tape.
Windshield Wiper Arm (3) - Install [2x]
- Clean the windshield wiper transmission pivot shaft splines with a soft wire brush before installing the windshield wiper arm (3).
- Position the windshield wiper arm (3) on the windshield wiper transmission pivot shaft.
- Windshield Wiper Arm Nut (2) - Install and tighten Fastener Specifications
- Windshield Wiper Arm Finish Cap (1) - Install
If required, realign the windshield wipers to their respective alignment circles (1) on the windshield.
- Lubricate the windshield with clean washer fluid.
- Run the windshield wipers for two complete cycles then turn off the windshield wipers.
- Ensure the windshield wipers are in the full park position.
- Inspect the windshield wipers for proper position to the alignment circles (1) on the windshield.
- Pressurize the fuel system and inspect for leaks.
This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.
Refer to Fastener Caution .
Alternately hand-tighten the fuel pump bolts one turn at a time until the pump is fully seated. Trying to draw down the pump without even side-to-side tightening may result in pump plunger damage.
This is a push nut.