High-Pressure Fuel Pump: Installation

WARNING: This page is about a different car, the 2024 Ford Transit-350 HD, 2024 Ford Transit-350, 2024 Ford Transit-250, and 2024 Ford Transit-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 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.

Courtesy of FORD MOTOR COMPANY
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 .

Courtesy of FORD MOTOR COMPANY
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 .

Courtesy of FORD MOTOR COMPANY
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 .

Courtesy of FORD MOTOR COMPANY
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 .

Courtesy of FORD MOTOR COMPANY
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.

Courtesy of FORD MOTOR COMPANY
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: 20 Nm Stage 2: 45deg.
2. Tighten the high-pressure fuel pump plate bolt.
  Torque : 10 Nm
Courtesy of FORD MOTOR COMPANY
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.

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 Formula below.

Courtesy of FORD MOTOR COMPANY
1. Tighten the high pressure fuel tube to high-pressure fuel pump flare nut. Refer to: SPECIFICATIONS .
  Torque : Stage 1: 10 Nm Stage 2: Tighten an additional 30 degrees or 50 Nm (37 lb-ft), whichever comes first. : 30deg.
2. Tighten the high pressure fuel tube bracket nut.
  Torque : 8 Nm
Courtesy of FORD MOTOR COMPANY
Connect the high-pressure fuel pump fuel feed tube quick release coupling. Refer to: Quick Release Coupling .

Courtesy of FORD MOTOR COMPANY
Connect the high-pressure fuel pump electrical connector.

Courtesy of FORD MOTOR COMPANY
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.

Courtesy of FORD MOTOR COMPANY
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 .