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: 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 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 Nm Stage 2: Tighten bolt 1: : 1 turn(s) Stage 3: Tighten bolt 2: : 1 turn(s) Stage 4: Repeat stages 2 and 3, until reaching: : 10 Nm Stage 5: Tighten bolts 1 and 2, in sequence an additional: : 45deg. Stage 6: Tighten bolt 3 to: : 12 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.
Follow the directions for the quick release coupling type 10. Install and connect the high-pressure fuel pump fuel feed coupling with the Oetiker® clamp end installed towards the port fuel rail. Refer to: Quick Release Coupling .
- Connect the high-pressure fuel pump electrical connector.
- Install the high-pressure fuel pump bracket then install and tighten the bolts.
Torque : 15 Nm
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NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas below.NOTE: Make sure that a new high-pressure fuel tube and a new retaining nut is installed.
- 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: : 9 Nm Stage 2: Tighten to: : 10 Nm Stage 3: Tighten an additional: : 30deg.
- Tighten the high-pressure fuel pump to fuel rail high-pressure fuel tube retaining nut.
Torque : 9 Nm
- Attach the fuel injector main harness retainer.
- Install the lower intake manifold. Refer to: Lower Intake Manifold .
- Connect the battery negative cable. Refer to the appropriate Battery Disconnect and Connect in General Procedures .
- Pressurize the fuel system. Refer to: Fuel System Pressure Release .