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 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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Lubricate the high-pressure fuel pump tappet and the high-pressure fuel pump drive unit bore with clean engine oil.

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NOTE: Align the notch on the high-pressure fuel pump tappet and with the groove in the high-pressure fuel pump drive unit bore.

Install the high-pressure fuel pump drive tappet.

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Install a new high-pressure fuel pump O-ring seal and lubricate with clean engine oil

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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 high-pressure fuel pump 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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Install the high-pressure fuel pump bracket, then install and tighten the high-pressure fuel pump bracket bolts.
Torque: 150 lb.in (17 Nm)

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1. NOTE: Make sure that a new high-pressure fuel tube is installed.
  
  Install the new high-pressure fuel tube, then install the high-pressure fuel tube flare nuts, the high-pressure fuel tube bracket bolt and the high-pressure fuel tube bracket nut finger tight at this stage.
2. NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas in illustration.
  
  Tighten the high-pressure fuel tube flare nuts in the following 3 stages.
  
  Torque:
  
  Stage 1: 62 lb.in (7 Nm)
  
  Stage 2: 133 lb.in (15 Nm)
  
  Stage 3: 30°
3. Tighten the high-pressure fuel tube bracket nut.
  Torque: 150 lb.in (17 Nm)
4. Tighten the high-pressure fuel tube bracket bolt.
  Torque: 89 lb.in (10 Nm)
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Install the high-pressure fuel pump drive unit noise insulator and install the brake vacuum pump noise insulator. Install the high-pressure fuel pump drive unit noise insulator retainer, install the brake vacuum pump noise insulator retainer and install the wire harness retainer.

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Connect the HO2S electrical connector retainer to the high-pressure fuel pump bracket.

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Connect the high-pressure fuel pump fuel supply hose. Refer to: Quick Release Coupling .

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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 high-pressure fuel pump electrical connector.

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Install the engine appearance cover, then install and tighten the engine appearance cover retaining nuts.
Torque: 80 lb.in (9 Nm)

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If equipped, install the strut tower cross brace and the new nuts.
Torque: 41 lb.ft (55 Nm)

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If equipped with strut tower cross brace, position the positive battery cable and attach the wiring harness retainer.

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Connect the negative and positive battery cables. Refer to: Battery Disconnect and Connect .
Pressurize the fuel system. Refer to: Fuel System Pressure Release .