High-Pressure Fuel Pump: Installation

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

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.

Using the crankshaft pulley bolt, turn the crankshaft until the high-pressure fuel pump drive lobe is at BDC.

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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.

Apply clean engine oil to the high-pressure fuel pump drive unit bore, the drive lobe and the roller tappet. Install the high-pressure fuel pump tappet.

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NOTE: Apply clean engine oil to the high-pressure fuel pump O-ring seals.

Install a new high-pressure fuel pump O-ring seal and lubricate with clean engine oil.

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Install the high-pressure fuel pump, then install and finger tighten the high-pressure fuel pump nuts. Alternately tighten each of the high-pressure fuel pump nuts one complete revolution until seated. Then tighten the fuel high-pressure fuel pump nuts in the following 2 stages.
Torque: Stage 1: 177 lb.in (20 Nm) - Stage 2: 45°

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Connect the high-pressure fuel pump fuel feed tube quick release coupling. Refer to: Quick Release Coupling .

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NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas in the chart below.

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NOTE: Make sure that a new high-pressure fuel pump-to-fuel rail high-pressure fuel tube is installed.

Install the high-pressure fuel pump-to-fuel rail high-pressure fuel tube and tighten the flare nuts finger tight, then tighten the flare nuts in the following 3 stages.

Torque: Stage 1: 62 lb.in (7 Nm) - Stage 2: 89 lb.in (10 Nm) - Stage 3: 25°

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Connect the high-pressure fuel pump electrical connector.

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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.

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1. Install the CAC intake pipe RH. Install and tighten the bolt.
  Torque: 71 lb.in (8 Nm)
2. Connect the bypass valve electrical connector.
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Attach the coolant hose to the starter motor bracket.

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1. Install the EVAP canister purge valve tube.Connect the EVAP canister purge valve quick release coupling. Refer to: Quick Release Coupling .
2. Attach the retainer.
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Tighten the CAC intake upper pipe RH clamp.
Torque: 44 lb.in (5 Nm)

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Tighten the CAC intake lower pipe RH clamp.
Torque: 44 lb.in (5 Nm)

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Tighten the CAC intake lower pipe RH clamp.
Torque: 44 lb.in (5 Nm)

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Install the lower RH air cleaner outlet pipe, install and tighten the bolt.
Torque: 71 lb.in (8 Nm)

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Connect the by-pass hose and the vacuum hose.

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Tighten the clamp.
Torque: 42 lb.in (4.8 Nm)

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Install the underbody shield, then install the retainers.

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Connect the battery. Refer to: Battery Disconnect and Connect .
Pressurize the fuel system. Refer to: Fuel System Pressure Release .