High-Pressure Fuel Pump: Installation
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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.
Turn the crankshaft until the high-pressure fuel pump drive lobe is at BDC (bottom dead center).
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NOTE: Align the key on the roller tappet with the keyway in the high-pressure fuel pump mounting pedestal bore.
Apply clean engine oil to the high-pressure fuel pump mounting pedestal bore, the drive lobe and the roller tappet. Install the high-pressure fuel pump roller tappet. Refer to: Specifications .
- Inspect the high-pressure fuel pump mounting plate seal and replace as needed. Lubricate the mounting plate seal with clean engine oil. Refer to: Specifications
.
- Install a new high-pressure fuel pump O-ring seal. Lubricate with clean engine oil. Refer to: Specifications
.
- Inspect the high-pressure fuel pump mounting plate O-ring seals and replace as needed. Lubricate with clean engine oil. Refer to: Specifications
.
- Install the high-pressure fuel pump mounting plate on to the high-pressure fuel pump. Install the high-pressure fuel pump bolts.
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- Install the high-pressure fuel pump with the mounting plate and the high-pressure fuel pump bolts, then finger tighten the high-pressure fuel pump bolts. Finger tighten the mounting plate bolt. Alternately tighten each high-pressure fuel pump bolt one complete revolution until seated. Tighten the fuel high-pressure fuel pump bolts in the following 2 stages.
Torque:Stage 1: 89 lb.in (10 Nm) Stage 2: 45 deg.
- Tighten the high-pressure fuel pump mounting plate bolt.
Torque: 89 lb.in (10 Nm)
- Install the high-pressure fuel pump with the mounting plate and the high-pressure fuel pump bolts, then finger tighten the high-pressure fuel pump bolts. Finger tighten the mounting plate bolt. Alternately tighten each high-pressure fuel pump bolt one complete revolution until seated. Tighten the fuel high-pressure fuel pump bolts in the following 2 stages.
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NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas below.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.
- Install the high-pressure fuel pump to fuel rail high-pressure fuel tube retaining bolts finger tight.
- Tighten the high-pressure fuel pump to fuel rail high-pressure fuel tube flare nuts in the following 3 stages.
- Stage 1: Tighten to: 62 lb.in (7 Nm).
- Stage 2: Tighten to: 89 lb.in (10 Nm).
- Stage 3: Tighten an additional 30 - 45 degrees and record the torque for each flare nut. 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.
- Tighten the high-pressure fuel pump to fuel rail high-pressure fuel tube retaining bolts in the following 2 stages.
Torque:Stage 1: 89 lb.in (10 Nm) Stage 2: 45 deg.
- Install the engine cover bracket, then install and tighten the retainers.
Torque: 89 lb.in (10 Nm)
- Follow the directions for the quick release coupling type 3. Install the crankcase ventilation tube and connect the crankcase ventilation tube. Refer to: Quick Release Coupling
.
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NOTE: The spring lock coupling must be installed onto the fuel tube end along the centerline. The assembly is complete when the tube end bottoms out on the spring lock coupling with an audible click / snap feel. Correct assembly should be verified by pulling back on the spring lock coupling end.
- Connect the high-pressure fuel pump supply line spring lock coupling. Refer to: Spring Lock Couplings .
- Install the secondary latch.
- Connect the high-pressure fuel pump electrical connector.
- Install the right engine compartment cover, them install and tighten the engine compartment cover retainers.
- Install the clips and the engine cover strut.
- Connect the battery. Refer to: Battery Disconnect and Connect .
- Pressurize the fuel system. Refer to: Fuel System Pressure Release .
- Install the engine appearance cover, then install and tighten the engine appearance cover retainers.
Torque: 89 lb.in (10 Nm)