High-Pressure Fuel Pump: Installation

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

All Vehicles

NOTE: Only rotate the crankshaft Clockwise (CW) or damage to the engine may occur.

NOTE: The drive lobe for the high-pressure fuel pump must be at BDC (bottom dead center) for the high-pressure fuel pump installation.

Using the crankshaft pulley bolt, turn the crankshaft until the high-pressure fuel pump drive lobe is at BDC (bottom dead center).

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Apply clean engine oil to the high-pressure fuel pump mounting pedestal bore, the drive lobe and the roller tappet. Refer to: Specifications .

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Install the high-pressure fuel pump roller tappet.

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NOTE: Apply clean engine oil to the high-pressure fuel pump O-ring seals.

Install a new high-pressure fuel pump O-ring seal and lubricate with clean engine oil. Refer to: Specifications .

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If removed, install and tighten the high-pressure fuel pump mounting studs.
Torque: 106 lb.in (12 Nm)

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Install the high-pressure fuel pump, then install the mounting nuts finger tight. Alternately tighten each high-pressure fuel pump nut one complete revolution until seated. Tighten the fuel high-pressure fuel pump nuts in the following 2 stages.
Torque : Stage 1: 177 lb.in (20 Nm) Stage 2: 45 deg.

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Connect the high-pressure fuel pump electrical connector.

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U611 Aviator
Position the high-pressure fuel pump shield so that the high-pressure fuel pump fuel feed can be connected.
Torque: 18 lb.ft (25 Nm)

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Connect the high-pressure fuel pump fuel feed spring lock coupling. Refer to: Spring Lock Couplings .

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U625 Explorer
Connect the high-pressure fuel pump fuel feed spring lock coupling. Refer to: Spring Lock Couplings .

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All Vehicles
Install the high-pressure fuel pump shield, then install and tighten the bolt.
Torque: 18 lb.ft (25 Nm)

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Install and tighten the high-pressure fuel pump shield nuts,
Torque: 18 lb.ft (25 Nm)

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NOTE: In stage 4, if the torque required to tighten any flare nut on the new high-pressure fuel tube reaches or exceeds 37 lb.ft (50 Nm), then that high pressure fuel tube must be discarded and replaced with another new high-pressure fuel tube.

NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas. Refer to the torque wrench adapter formula in the graphic below.

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

Install the high-pressure fuel tube and bracket nuts, tighten the high-pressure fuel tube flare nuts and bracket nuts finger tight.

Torque : Stage 1: Tighten the high-pressure fuel tube bracket nuts to, : 89 lb.in (10 Nm) Stage 2: Tighten the high-pressure fuel tube flare nuts to, : 62 lb.in (7 Nm) Stage 3: Tighten the high-pressure fuel tube flare nuts to, : 89 lb.in (10 Nm) Stage 4: Tighten the high-pressure fuel tube flare nuts an additional, : 25 deg.

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NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.

Install the fuel injection pump noise insulator.

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Install the intake manifold. Refer to: Intake Manifold .
Attach the coolant hose retainer.

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With hybrid engine only, install the harness, then install and tighten the wire harness retaining nut.
Torque: 106 lb.in (12 Nm)

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Install the cowl panel. Refer to: Cowl Panel .
Connect the battery negative cable. Refer to: Battery Disconnect and Connect .
Pressurize the fuel system. Refer to: Fuel System Pressure Release .