High Pressure Fuel Pump 2 (G2796615): Installation

The following step(s) applies to: 

All vehicles 

1. CAUTION:

   • Make sure that all the mating faces are clean and free of any foreign material.
   • Make sure that the components have been thoroughly cleaned and inspected before installing to the engine. Failure to follow this instruction might result in premature engine failure.

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   • Lubricate the HP  fuel pump tappet with clean engine oil.

     Refer to: SPECIFICATIONS

   • Install the HP  fuel pump tappet.
2. CAUTION: Tighten the bolts a turn at a time until the correct torque is achieved.
   NOTE: Lubricate the HP  fuel pump O-ring seal with clean engine oil.

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   Tighten the 2 HP  fuel pump bolts.

   Torque  : 11 Nm 

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   Loosen the 2 bolts.

   Torque  : -1 turn(s) 

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   Install the HP  fuel pump cover.

5. CAUTION: Install new HP  fuel supply lines.
   NOTE: Remove and discard the blanking caps.

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   • Install the HP  fuel line assembly to the upper camshaft cover stud.

     Renew Part: Fuel injector high pressure pipe(s) Quantity: 1  .

   • Connect and finger tighten the 2 HP  fuel line unions.
   • Install and finger tighten the 2 bolts.
6. NOTE:

   • Do not tighten at this stage.
   • Remove and discard the blanking caps.

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   Connect and finger tighten the HP  fuel line union.

7. CAUTION: Care must be taken when positioning the HP  fuel pump cover to one side.
   NOTE: HP  fuel pump cover shown removed for clarity.

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   Tighten the 2 bolts.

   Torque  : 11 Nm 

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   • Tighten the 3 HP  fuel line unions in the sequence illustrated.

     Torque  : 20 Nm 

   • Tighten the 2 HP  fuel line bracket bolts in the sequence illustrated.

     Torque 

     M6: 12 Nm 

     M8: 25 Nm 

   • Tighten the upper nut in the sequence illustrated.

     Torque 

     M5: 6 Nm 

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   • Connect and tighten the 2 LP  fuel line unions as illustrated.

     Torque  : 20 Nm 

   • Install and tighten the LP  fuel line bracket bolt as illustrated.

     Torque 

     M6: 12 Nm 

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    • Install the HP  fuel line cover.
    • Install and tighten the 2 bolts.

      Torque 

      M10: 29 Nm 

      M6: 11 Nm 

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    • Reposition the wiring harness to the original position.
    • Secure the 4 wiring harness clips as illustrated.
    • Connect the 2 electrical connectors.

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    Install the engine mount bracket.

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    Install and tighten the 4 engine mount bracket bolts.

    Torque 

    Stage 1: 45 Nm 

    Stage 2: 60° 

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    Remove the engine support.

    General Equipment: Transmission jack 

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    Install and tighten the engine mount nut.

    Torque  : 180 Nm 

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    • Reposition and secure the ground cable to the original position.
    • Install and tighten the bolt.

      Torque  : 9 Nm 

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    • Install the idler pulley bracket.
    • Install and tighten the 3 bolts.

      Torque  : 25 Nm 

    The following step(s) applies to: 

    Right hand drive vehicles 

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    • Install the steering column shaft.
    • Install and tighten a new steering column lower shaft lower bolt.

      Renew Part: Steering column lower shaft lower bolt Quantity: 1  .

      Torque  : 30 Nm 

    The following step(s) applies to: 

    All vehicles 

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    • Reposition the wiring harness to the original position.
    • Secure the clip.

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    • Connect and finger tighten the 2 fuel crossover line unions as illustrated.
    • Install and tighten the 4 fuel crossover line bracket bolts in the sequence illustrated.

      Torque 

      M6: 12 Nm 

    • Tighten the 2 fuel crossover line unions in the sequence illustrated.

      Torque  : 20 Nm 

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    • Reposition the wiring harness to the original position.
    • Secure the 2 clips.
    • Connect the 4 electrical connectors.

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    • Reposition the breather pipe to the original position.
    • Secure the clip.
    • Connect the breather pipe connector.

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    • Remove the oil filler cap.
    • Install the left coil cover as illustrated.
    • Secure the 2 upper clips.
    • Secure the 2 lower studs.
    • Install the oil filler cap.

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    • Connect the 2 fuel line connectors.
    • Secure the 2 fuel lines to the left coil cover.
    • Secure the 2 fuel line clips.

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    • Install the left differential pressure sensor assembly.
    • Install and tighten the 2 nuts.

      Torque  : 9 Nm 

    • Connect the hose.
    • Secure the clip.
    • Connect the electrical connector.

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    • Install the right coil cover as illustrated.
    • Secure the 4 lower clips.
    • Secure the stud.
    • Secure the 3 upper clips.

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    • Reposition the vacuum pipe to the original position.
    • Secure the vacuum pipe to the right coil cover.

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    • Install the right differential pressure sensor assembly.
    • Install and tighten the bolt.

      Torque  : 9 Nm 

    • Connect the hose.
    • Secure the clip.
    • Connect the electrical connector.

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    • Secure the cable bracket assembly to the original position.
    • Install and tighten the 2 nuts.

      Torque  : 9 Nm 

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    • Reposition the coolant pipe assembly to the original position.
    • Install the coolant pipe assembly as illustrated.
    • Connect the 5 coolant pipe connectors.
    • Secure the 2 clips.
31. Install the air cleaner outlet pipe T-connector.

    Refer to: AIR CLEANER OUTLET PIPE T-CONNECTOR

32. Install the generator.

    Refer to: GENERATOR

33. Install the starter motor.

    Refer to: STARTER MOTOR

34. Connect the 12 V system.

    Refer to: 12V SYSTEM DISCONNECT AND CONNECT

35. Bleed the fuel system.

    Refer to: LOW-PRESSURE FUEL SYSTEM BLEEDING

    Refer to: HIGH-PRESSURE FUEL SYSTEM BLEEDING