High-Pressure Fuel Pump: Installation

WARNING: This page is about a different car, the 2020 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

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.

With the help of an assistant, using the crankshaft pulley bolt, turn the crankshaft until the high-pressure fuel pump drive lobe is at BDC.

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

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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 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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Install the high-pressure fuel pump, then install and finger tighten the high-pressure fuel pump nuts. Alternately tighten each of the high-pressure fuel pump nuts one complete revolution until seated. Then 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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NOTE: In stage 3, if the torque required to tighten any flare nut on the new high-pressure fuel tube reaches or exceeds 55 lb.ft (75 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 in the chart below.

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

Install the high-pressure fuel pump to fuel rail high-pressure fuel tube and tighten the flare nuts finger tight, then tighten the flare nuts in the following 3 stages.

Torque

:Stage 1: 62 lb.in (7 Nm) | Stage 2: 89 lb.in (10 Nm) | Stage 3: Tighten an additional : 25 deg.

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Connect the high-pressure fuel pump electrical connector.

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Install the fuel supply manifold, then install and tighten the retainers.
Torque

: 89 lb.in (10 Nm)

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Connect the fuel supply spring lock coupling. Connect the fuel supply quick connect couplings. Attach the wire harness retainers. Refer to: Spring Lock Couplings . .

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Install the spring lock coupling retaining clips.

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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 high-pressure fuel pump shield, then install and tighten the retainers.
Torque

: 89 lb.in (10 Nm)

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Attach the wiring harness retainers.

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Install the coolant tube, then connect the coolant hoses and the coolant hose clamps. Connect the quick release coupling. Refer to QUICK RELEASE COUPLING

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Install the intake manifold. Refer to: Intake Manifold .
Connect the battery negative cable. Refer to: Battery Disconnect and Connect .
Pressurize the fuel system. Refer to: Fuel System Pressure Release .
Fill and bleed the cooling system. Refer to ENGINE COOLING SYSTEM DRAINING, VACUUM FILLING AND BLEEDING