High-Pressure Fuel Pump: Installation

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

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 (bottom dead center) for the high-pressure fuel pump installation.

Using the crankshaft pulley bolt, turn the crankshaft until the high-pressure fuel pump cam lobe is at BDC.

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

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Inspect the high-pressure fuel pump mounting plate seal and replace as necessary. Lubricate the fuel injection pump mounting plate seal with clean engine oil. Refer to: Specifications .

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

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

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NOTE: Apply clean engine oil to the fuel injection pump mounting plate O-ring seals.

Inspect the high-pressure fuel pump mounting plate O-ring seals and replace as necessary. Lubricate with clean engine oil. Refer to: Specifications .

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

Install the high-pressure fuel pump mounting plate on to the high-pressure fuel pump. Install the new high-pressure fuel pump bolts.

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1. Install the high-pressure fuel pump with the high-pressure fuel pump mounting plate, loosely install the new high-pressure fuel pump bolts and loosely install the high-pressure fuel pump plate bolt. Alternately tighten each high-pressure fuel pump bolt one complete revolution until seated. Tighten the fuel high-pressure fuel pump bolts in the following 2 stages.
  Torque:
  
  Stage 1: 177 lb.in (20 Nm)
  
  Stage 2: 45°
2. Tighten the high-pressure fuel pump plate bolt.
  Torque: 89 lb.in (10 Nm)
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NOTE: Apply clean engine oil to the threads of the high-pressure fuel tube flare nut.

NOTE: Install the high pressure fuel tube flare nut and the new high pressure fuel tube bracket nut finger tight at this stage. Tighten in the stages shown in illustration.

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

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

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Tighten the high pressure fuel tube to high-pressure fuel pump flare nut. Refer to: Specifications .
Torque:

Stage 1: 89 lb.in (10 Nm)

Stage 2: Tighten an additional 30 degrees or 50 Nm (37 lb-ft), whichever comes first. : 30°
Tighten the high pressure fuel tube bracket nut.
Torque: 71 lb.in (8 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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Connect the high-pressure fuel pump electrical connector.

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

Install the high-pressure fuel pump noise insulator.

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Connect the battery. Refer to: Battery Disconnect and Connect - Vehicles With: Single Battery . Refer to: Battery Disconnect and Connect - Vehicles With: Dual Batteries .
Pressurize the fuel system. Refer to: Fuel System Pressure Release .