Installation Procedure
Mark the NEW high pressure diesel fuel pump shaft in the same position as the marks on the old high pressure diesel fuel pump for ease of installation and ensuring it is timed correctly with the engine timing.
Lubricate the high pressure diesel fuel pump shaft (3). Adhesives, Fluids, Lubricants, and Sealers
Use the marks on the pump shaft and the sprocket to align and install the high pressure diesel fuel pump (1).
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Install the 3 fuel injection pump bolts (1) and tighten. Fastener Specifications
- Connect the electrical connectors to the engine coolant temperature sensor and the block heater.
- Position the hoses and harness as needed.
Connect the 2 high pressure diesel fuel pump electrical connectors (1).
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Install a NEW fuel injection pump bolt (1) and tighten. Fastener Specifications
- Remove the EN-52448-1 High Pressure Fuel Pump Tool.
Fuel Pump Access Hole Cover Seal (3) - Install NEW
- Fuel Pump Access Hole Cover (2) - Install
- Timing Chain Cover Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Transmission - Install - Automatic Transmission Removal and Installation (LM2, 2WD with F47)Automatic Transmission Removal and Installation (LM2, 2WD without F47)Automatic Transmission Removal and Installation (L84, L87, 2WD with F47)Automatic Transmission Removal and Installation (L84, L87, 2WD without F47)
Install a NEW high pressure diesel fuel feed to rail pipe (2)
- Hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel injection rail.
Install the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1) and tighten. Fastener Specifications
- Attach the fuel injector fuel return pipe retainer (2).
Install the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1) and tighten. Fastener Specifications
Hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel pump.
- Tighten the high pressure diesel fuel feed to rail pipe fittings to both the high pressure diesel fuel pump and the high pressure diesel fuel injection rail. Fastener Specifications
Diesel Fuel Separator (1) - Install
- Diesel Fuel Separator (1) - Connect - Metal Collar Quick Connect Fitting Service
Diesel Fuel Separator Bracket Bolt (1) - Install and tighten - Fastener Specifications
Fuel Injection Fuel Return Pipe (2) - Install
- Fuel Injector Fuel Return Pipe Clamp (1) - Engage - Hose Clamp Replacement Guidelines - Spring Type
Fuel Return Pipe (1) @Diesel Fuel Separator - Connect - Metal Collar Quick Connect Fitting Service
- Fuel Pump Fuel Feed Hose (1) - Install
- Fuel Pump Fuel Feed Hose (1) - Connect [2x] - Metal Collar Quick Connect Fitting Service
Fuel Feed Pipe Clip Bolt (1) - Install and tighten - Fastener Specifications
- Front Wheelhouse Liner-Left Side - Install - Front Wheelhouse Liner Replacement
- 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.
Camshaft Housing Cover Insulator (1) - Install
Exhaust Gas Recirculation Pipe Bracket (5) - Install
- Exhaust Gas Recirculation Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
- Reposition harness, hoses, and connect electrical connectors as needed.
Charge Air Cooler Bracket (2) - Install
- Charge Air Cooler Bracket Bolt (1) - Install and tighten [5x] - Fastener Specifications
Engine Coolant Air Bleed Hose Clip (1) - Install
Oil Filler Tube Support Stud (1) - Install and tighten - Fastener Specifications
Engine Wiring Harness Bracket (3) - Install
- Engine Wiring Harness Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
Turbocharger Bracket Bolt (1) - Install and tighten - Fastener Specifications
Intake Manifold Resonator (2) - Install
- Engage the retaining spring (1).
Turbocharger Heat Shield (1) - Install
Turbocharger Heat Shield Nut (2) - Install and tighten - Fastener Specifications
- Turbocharger Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
Upper Intake Manifold Bracket (2) - Install
- Upper Intake Manifold Brace Nut (1) - Install and tighten [3x] - Fastener Specifications
Charge Air Cooler (1) - Install
Charge Air Cooler Bolt (1) - Install and tighten [4x] - Fastener Specifications
Charge Air Cooler Inlet Air Hose (2) - Install
- Charge Air Cooler Inlet Air Hose Clamp (1) - Tighten [2x] - Fastener Specifications
Charge Air Cooler Outlet Air Hose (2) - Install
- Charge Air Cooler Outlet Air Hose Clamp (1) - Tighten [2x] - Fastener Specifications
Connect the nitrogen oxides sensor electrical connector.
- Wiring Harness Retainer (4) @Charge Air Cooler - Install
Wiring Harness Retainer (2) @Charge Air Cooler - Install [3x]
- Electrical Connector (1) @Charge Air Cooler - Connect [2x]
Install a NEW exhaust gas recirculation cooler inlet pipe gasket (3).
- Install a NEW exhaust gas recirculation pipe seal (2).
- Install the exhaust gas recirculation pipe (1).
- NOTE:
Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.
Exhaust Gas Recirculation Pipe Bolt (1) - Install and tighten - Fastener Specifications
Exhaust Gas Recirculation Outlet Pipe Bolt (1) - Install and tighten [2x] - Fastener Specifications .
Exhaust Gas Recirculation Outlet Pipe Bolt (2) - Install and tighten - Fastener Specifications
- Install the turbocharger coolant return hose clip (1).
Turbocharger Coolant Feed and Return Pipe Bolt (3) - Install and tighten - Fastener Specifications
Install and tighten the 2 exhaust gas recirculation pipe bolts (1). Fastener Specifications
Engine Coolant Air Bleed Hose (2) - Reposition
- Engine Coolant Outlet Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
Install the rear engine wiring harness channel (2).
- Engine Wiring Harness Bracket Nut (1) - Install and tighten [3x] - Fastener Specifications .
Air Cleaner Outlet Duct (2) - Install
- Air Cleaner Outlet Duct Clamp (1) - Tighten - Fastener Specifications
Air Cleaner Outlet Front Duct (2) - Install
- Air Cleaner Outlet Duct Clamp (1) - Tighten [2x] - Fastener Specifications
Oil Filler Cap - Remove
- Intake Manifold Cover (2) - Install
- Intake Manifold Cover Bolt (1) - Install and tighten - Fastener Specifications
- Oil Filler Cap - Install
- Plenum Front Panel Outer Reinforcement - Install - Plenum Front Panel Outer Reinforcement Removal and Installation
- Lower the vehicle.
- Prime the fuel system and inspect for leaks. Fuel System Priming
- Perform the high pressure fuel variable reset. High Pressure Fuel Variable Reset
Refer to Fastener Caution .
Refer to Torque-to-Yield Fastener Caution .