High-Pressure Fuel Pump: Installation
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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 (bottom dead center).
- 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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NOTE: The roller tappets roller goes down towards the camshaft.NOTE: Align the notch on the high-pressure fuel pump tappet with the groove in the high-pressure fuel pump drive unit bore.
Install the high-pressure fuel pump roller tappet.
- Inspect the high-pressure fuel pump mounting plate seal, clean and replace as needed. Lubricate the seal with clean engine oil. Refer to: Specifications
.
- Install a new high-pressure fuel pump O-ring seal. Lubricate with clean engine oil. Refer to: Specifications
.
- Inspect the high-pressure fuel pump mounting plate O-ring seals, clean and replace as needed. Lubricate with clean engine oil. Refer to: Specifications
.
- Install the high-pressure fuel pump mounting plate on to the high-pressure fuel pump. Install the new high-pressure fuel pump bolts.
- Install the high-pressure fuel pump with the mounting plate and the bolts. Tighten the fuel high-pressure fuel pump bolts in the following 5 stages.
Torque
:Stage 1: Finger tighten all of the bolts : 0 lb.in (0 Nm)
Stage 2: Tighten bolt 1 : 1turn(s)
Stage 3: Tighten bolt 2 : 1turn(s)
Stage 4: Repeat stages 2 and 3, until reaching : 89 lb.in (10 Nm)
Stage 5: Tighten bolts 1 and 2, in sequence an additional : 45°
- Tighten the high-pressure fuel pump mounting plate bolt.
Torque
: 89 lb.in (10 Nm)
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NOTE: The high-pressure fuel pump supply tube must be installed with the Oetiker® clamp end installed to the port fuel rail; if it is installed backwards a check valve will prevent the engine from running properly.
Install and connect the high-pressure fuel pump fuel feed quick release coupling with the Oetiker® clamp end installed towards the port fuel rail. Follow the directions for the quick release coupling type 10. Refer to: Quick Release Coupling .
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NOTE: Make sure that a new high-pressure fuel tube and a new retaining nut is installed.
- Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas in illustration.
- Install the new high-pressure fuel tube and tighten the flare nuts finger tight.
- Install new the high-pressure fuel tube retaining nut finger tight.
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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.
Tighten the high-pressure fuel tube flare nuts in the following 3 stages.
Torque
:Stage 1: Tighten to : 80 lb.in (9 Nm)
Stage 2: Tighten to : 89 lb.in (10 Nm)
Stage 3: Tighten an additional : 30°
- Tighten the high-pressure fuel pump to fuel rail high-pressure fuel tube retaining nut.
Torque
: 71 lb.in (8 Nm)
- Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas in illustration.
- Attach the harness retainer.
- Install the lower intake manifold. Refer to: Lower Intake Manifold .
- Connect the high-pressure fuel pump electrical connector.
- Connect the battery negative cable. Refer to: Battery Disconnect and Connect .
- Pressurize the fuel system. Refer to: Fuel System Pressure Release .