High-Pressure Fuel Pump: Installation

Remove the fasteners and position the fender splash shield aside.

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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.

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

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Position the fender splash shield and install the retainers.

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

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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 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: Tighten to: : 177 lb.in (20 Nm) Stage 2: Tighten an additional: : 45 deg.

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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: 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.

NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas. Refer to the torque wrench adapter formula in the graphic 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: Tighten to: : 62 lb.in (7 Nm) Stage 2: Tighten to: : 89 lb.in (10 Nm) Stage 3: Tighten an additional: : 25 deg.

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Connect the high-pressure fuel pump electrical connector.

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Install the charge air cooler (CAC) intake pipe - RH. Refer to: CHARGE AIR COOLER (CAC) INTAKE PIPE
Connect the battery. Refer to: BATTERY DISCONNECT AND CONNECT
Pressurize the fuel system. Refer to: Fuel System Pressure Release