Fuel Pump Installation
Special Tools
EN 48896 HP Fuel Pump Installation Alignment Gauge
For equivalent regional tools, refer to Special Tools .
- Use the EN 48896 alignment gauge (2) to ensure that the camshaft lobe is in the base circle position. At base circle position, the tool will be flush with the head (1).
- Lubricate the high pressure fuel pump cylinder head bore with clean engine oil.
- Lubricate the high pressure fuel pump roller lifter with clean engine oil and install into the cylinder head bore.
- Install a NEW high pressure fuel pressure fuel pump gasket (4).NOTE:
If a high pressure pump is replaced on an engine which originally had a pump WITH a gasket, it must be rebuilt WITH a pump kit that includes the gasket; if a high pressure pump is replaced on an engine which originally had a pump WITHOUT a gasket, it must be rebuilt WITHOUT a gasket.
- Lubricate NEW high pressure fuel pump O-ring (5) with one drop of clean engine oil and install.
- Install the valve lifter follower (3).
- Install the high pressure fuel pump (2).
- Start and hand-tighten the high pressure fuel pump bolts (1) evenly.
- Tighten the fuel pump bolts (1) a first pass in sequence to 15 N.m (11 lb ft).
- Tighten the fuel pump bolts (1) a second pass in an additional 60 degrees.
- DO NOT reuse the high pressure fuel rail crossover pipe.
- The tightening order and torque are critical to proper fuel system fit and function. Be sure to follow installation and tightening steps exactly.
- Install the NEW high pressure LH to RH fuel rail crossover pipe by starting all three fuel crossover pipe fitting nuts (1), (2) and (3) to finger-tight only.
- Tighten the fuel rail crossover pipe fittings to 28 N.m (21 lb ft) in the following order: (1) left fuel rail, (2) right fuel rail, then (3) fuel pump.
- Install the NEW fuel feed pipe (2) by installing the fuel line nut to the fuel pump finger-tight.
- Install the fuel feed pipe bolts finger tight (1 and 3).
- Tighten the fuel feed pipe bolts (1 and 3) to 50 N.m (37 lb ft).
- Tighten the fuel feed pipe fitting nut to 28 N.m (21 lb ft).
- Install the fuel rail wiring connectors to the fuel feed pipe bracket.
- Install the fuel rail noise shield (1).
The camshaft must be in the base circle position before the high pressure fuel pump is installed.
Ensure that the high pressure fuel pump roller lifter is oriented properly, the camshaft is at base circle and the number 1 piston is at top dead center (TDC) on the exhaust stroke.
Ensure the plastic bolt retainers are installed in the high pressure fuel pump mounting holes before installing.
Refer to Fastener Caution .
Alternately hand-tighten the fuel pump bolts one turn at a time until the pump is fully seated. Trying to draw down the pump without even side-to-side tightening may result in pump plunger damage.
This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.