High-Pressure Fuel Pump: Installation

WARNING: This page is about a different variant/trim than selected.

Remove and discard the high-pressure fuel pump O-ring seal.

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Remove the high-pressure fuel pump drive tappet.

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If any flat spots or scoring, especially in the indicated areas is found, inspect the high-pressure fuel pump and the high-pressure fuel pump tappet drive lobe. Install new components as necessary.

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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.

Rotate the camshaft as necessary until the cam lobe for the high-pressure fuel pump is at BDC.

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1. Lubricate the high-pressure fuel pump tappet and the high-pressure fuel pump drive unit bore with clean engine oil.
  Material
  
  : Motorcraft® SAE 5W-30 Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)
2. Install the high-pressure fuel pump tappet.
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Install a new high-pressure fuel pump O-ring seal.
Material

: Motorcraft® SAE 5W-30 Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

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NOTE: Make sure that new high-pressure fuel pump bolts are installed.

Install the high-pressure fuel pump and loosely install the new high-pressure fuel pump bolts, alternately tighten each bolt one complete revolution until seated. Tighten the high-pressure fuel pump bolts in the following 2 stages.

Torque

:Stage 1: 44 lb.in (5 Nm) Stage 2: 55°

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1. Install the high-pressure fuel pump bracket, then install and tighten the high-pressure fuel pump bracket bolts.
  Torque
  
  : 150 lb.in (17 Nm)
- Attach the harness retainer to the high-pressure fuel pump bracket.
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NOTE: Only tighten the high pressure fuel tube flare nuts finger tight at this stage.

NOTE: Only tighten the high pressure fuel tube bracket bolts finger tight at this stage.

Install the following items:

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

Install the new high-pressure fuel tube.

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

Tighten the high-pressure fuel tube flare nuts in the following 2 stages.

Torque

:Stage 1: 133 lb.in (15 Nm) Stage 2: 30°

Tighten the high-pressure fuel tube bracket bolts.
Torque

: 89 lb.in (10 Nm)

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Connect the high-pressure fuel pump fuel feed tube quick release coupling. Refer to: Quick Release Coupling .

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Attach the EVAP canister purge valve to the EVAP canister purge valve bracket, connect the EVAP canister purge valve electrical connector.

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NOTE: Use care when installing the high-pressure fuel pump noise insulator. Spreading the openings will aid in installing the high-pressure fuel pump noise insulator and reduce the risk of damage.
1. Install the high-pressure fuel pump noise insulator.
2. Connect the high-pressure fuel pump electrical connector.
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Install the air cleaner outlet pipe.
1. Install the air cleaner outlet pipe and tighten the clamps.
  Torque
  
  : 44 lb.in (5 Nm)
2. Install and tighten the air cleaner outlet pipe bolt.
  Torque
  
  : 44 lb.in (5 Nm)
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Reconnect the battery. Refer to: Battery Disconnect and Connect .
Pressurize the fuel system. Refer to: Fuel System Pressure Release .