Front High Pressure Fuel Pump (G2268898): Installation

WARNING: This page is about a different variant/trim than selected.

NOTE: Lubricate the High Pressure (HP) fuel pump tappet with clean engine oil.

Install the High Pressure (HP) fuel pump tappet.
CAUTION: Tighten the bolts a turn at a time until the correct torque is achieved.

NOTE: Lubricate the High Pressure (HP) fuel pump O-ring seal with clean engine oil.
- Install the HP fuel pump.
- Install and tighten the 2 bolts.
  Torque : 11 Nm
Install the Noise, Vibration and Harshness (NVH) material to the HP fuel pump.
CAUTION:
- Lubricate only the union threads with clean engine oil.
- Do not tighten the bolts at this stage.
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- Install new HP fuel delivery lines.
  Renew Part: Fuel rail supply pipe(s) Quantity: 1 .
- Install the 2 bolts.
- Install the nut.
CAUTION: Do not tighten the fuel union at this stage.

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Install the union to the fuel rail.
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- Tighten the fasteners in the sequence shown.
  Torque
  
  Fuel unions (1): 21 Nm
  
  M6 (2): 11 Nm
  
  M8 (3): 25 Nm
  
  M5 (4): 6 Nm
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Check the unions for correct torque values.

Torque : 21 Nm
CAUTION: Do not tighten the fuel unions at this stage.

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Install the 2 fuel line unions.
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- Install and tighten the bolt.
  Torque : 12 Nm
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- Tighten the 2 fuel line unions.
  Torque : 21 Nm
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- Install the fuel line heatshield.
- Install and tighten the 2 bolts.
  Torque
  
  M10: 29 Nm
  
  M6: 11 Nm
- Reposition the wiring harness.
- Secure the 3 clips.
- Connect the 2 electrical connectors.
CAUTION: Inspect the seal, install a new component if damaged.

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- Install a new O-ring seal.
  Renew Part: Halfshaft support bracket o-ring seal Quantity: 1 .
- Install the halfshaft support bracket.
- Install and tighten the 3 bolts.
  Torque : 25 Nm
- Install the engine mount bracket.
- Install and tighten the 2 bolts.
  Torque : 48 Nm
Secure the clip to the engine mount bracket.
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- Install and tighten the 2 bolts.
  Torque : 48 Nm
Remove the transmission jack.
General Equipment: Transmission jack
- Install the idler pulley.
- Install and tighten the 3 bolts.
  Torque : 25 Nm
Install the generator.
Refer to: REMOVAL AND INSTALLATION .
Install the front right halfshaft.
Refer to: FRONT HALFSHAFT .
- Install and tighten the engine mount top nut.
  Torque : 48 Nm
CAUTION:
- Fuel pipe can be re-used, inspect for signs of damage. Renew if necessary.
- Do not tighten the fasteners at this stage.
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- Install the fuel line.
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Tighten the fasteners in the sequence illustrated.

Torque

M6 x 20 bolts: 11 Nm

Fuel unions: 21 Nm
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Check the fuel unions for correct torque values.
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Secure the clip.
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Install the NVH material.
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Connect the vacuum pipe.
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Connect the 2 coolant hoses to the charge air cooler.
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- Install the NVH material.
- Install the oil filler cap.
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Secure the 2 fuel lines.
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Connect the 2 coolant hoses to the left side of the charge air cooler.
Install the air filter outlet pipe T-connector.
Refer to: AIR FILTER OUTLET PIPE T-CONNECTOR .
Connect the startup battery ground cable.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT .
Fill and bleed the cooling system.
Refer to: COOLING SYSTEM PARTIAL DRAINING AND VACUUM FILLING .
CAUTION: Make sure the vehicle is leveled.
- Fill the engine with the correct engine oil for the vehicle.
  Refer to: SPECIFICATIONS .
- Clean any residual engine oil from the oil filler cap area.
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Install the oil filler cap.
CAUTION:
- Make sure that the vehicle has been left for 5 minutes from filling with oil.
- Make sure the engine oil level is reading at least minimum (by following Steps 6-13), before starting the engine.
- Start the engine and allow to run for 10 minutes, stop the engine.
- Check for any leaks.
CAUTION: Make sure that the selector lever and the gearshift mechanism are in the Park (P) position.

Turn on the ignition.
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Press the menu switch to access the main menu display.
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Scroll down the menu to the 'Vehicle Info' selection.
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Press the menu switch to access the 'Vehicle Info' display.
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Scroll down the menu to the 'Oil Level' selection.
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- Press the menu switch to access the oil level display.
- If the engine oil level is not available, it will be necessary to update the oil level value.
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- Press the speed control cancel switch 2 times to update the engine oil level value.
- Check that the engine oil level display shows an oil level reading.
- If necessary top up with engine oil.
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- Allow 10 minutes for the engine oil level to stabilize if there has been additional engine oil top up. Repeat steps 6- 13.
- Make sure that the average engine oil level value has now been updated.
WARNING: After the repairs are done, the fuel system must be checked visually for leaks. Failure to follow these instructions may result in personal injury.

Install the engine undershield.

Refer to: ENGINE UNDERSHIELD - V8 S/C 5.0L PETROL .