High-Pressure Fuel Pump: Installation

WARNING: This page is about a different car, the 2021 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Only rotate the crankshaft clockwise or damage to the engine may occur.

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

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

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Apply clean engine oil to the high-pressure fuel pump mounting pedestal bore, the drive lobe and all of 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.

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Install a new high-pressure fuel pump O-ring seal. 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

: 53 lb.in (6 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: Tighten to : 89 lb.in (10 Nm)

Stage 2: Tighten an additional : 30°

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NOTE: In stage 7, 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: Do not use oil on the threads.

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

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

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

Torque

:Stage 1: Tighten the upper high-pressure fuel tube bolt to : 89 lb.in (10 Nm)

Stage 2: Tighten the upper high-pressure fuel tube bolt an additional : 30°

Stage 3: Tighten the lower high-pressure fuel tube bolt to : 89 lb.in (10 Nm)

Stage 4: Tighten the lower high-pressure fuel tube bolt an additional : 30°

Stage 5: Tighten the high-pressure fuel tube flare nuts to : 71 lb.in (8 Nm)

Stage 6: Tighten the high-pressure fuel tube flare nuts to : 89 lb.in (10 Nm)

Stage 7: Tighten the high-pressure fuel tube flare nuts an additional : 25°

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Connect the electrical connector, then attach the wiring harness retainer,

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

: 89 lb.in (10 Nm)

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Attach the wiring harness retainer to high-pressure fuel line shield.

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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.

Connect the high-pressure fuel pump fuel feed quick release coupling. Follow the directions for the quick release coupling type 2. Refer to: Quick Release Coupling .

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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, then engage the retainer.

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Connect the high-pressure fuel pump electrical connector.

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Inspect the ignition coil-on-plug assembly for cracks, rips, or tears. Replace any damaged coil-on-plug assemblies.

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NOTE: Ensure that the ignition coil-on-plug is fully seated on the spark plug by pushing down on the boot end until it stops.

Install the ignition coil-on-plugs, then install and tighten the bolts.

Torque

: 89 lb.in (10 Nm)

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Connect the ignition coil-on-plug electrical connectors.

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Install the intake manifold. Refer to: Intake Manifold .
Pressurize the fuel system. Refer to: Fuel System Pressure Release .