High-Pressure Fuel Pump: Installation

All Vehicles 

1. 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 (bottom dead center).

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2. Apply clean engine oil to the high-pressure fuel pump mounting pedestal bore, the drive lobe and the roller tappet. Refer to: Specifications .

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3. Install the high-pressure fuel pump roller tappet.

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4. 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. Refer to: Specifications .

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5. If removed, install and tighten the high-pressure fuel pump mounting studs.

   Torque: 106 lb.in (12 Nm)

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6. Install the high-pressure fuel pump, then install the mounting nuts finger tight. Alternately tighten each high-pressure fuel pump nut one complete revolution until seated. 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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7. Connect the high-pressure fuel pump electrical connector.

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   U611 Aviator 

8. Position the high-pressure fuel pump shield so that the high-pressure fuel pump fuel feed can be connected.

   Torque: 18 lb.ft (25 Nm)

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9. Connect the high-pressure fuel pump fuel feed spring lock coupling.

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   U625 Explorer 

10. Connect the high-pressure fuel pump fuel feed spring lock coupling.

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    All Vehicles 

11. Install the high-pressure fuel pump shield, then install and tighten the bolt.

    Torque: 18 lb.ft (25 Nm)

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12. Install and tighten the high-pressure fuel pump shield nuts,

    Torque: 18 lb.ft (25 Nm)

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13. NOTE: In stage 4, if the torque required to tighten any flare nut on the new high-pressure fuel tube reaches or exceeds 37 lb.ft (50 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 below.

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

    Install the high-pressure fuel tube and bracket nuts, tighten the high-pressure fuel tube flare nuts and bracket nuts finger tight.

    Torque: Stage 1: Tighten the high-pressure fuel tube bracket nuts to, : 89 lb.in (10 Nm) | Stage 2: Tighten the high-pressure fuel tube flare nuts to, : 62 lb.in (7 Nm) | Stage 3: Tighten the high-pressure fuel tube flare nuts to, : 89 lb.in (10 Nm) | Stage 4: Tighten the high-pressure fuel tube flare nuts an additional, : 25°

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14. NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.

    Install the fuel injection pump noise insulator.

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15. Install the intake manifold. Refer to: INTAKE MANIFOLD
16. Attach the coolant hose retainer.

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17. With hybrid engine only, install the harness, then install and tighten the wire harness retaining nut.

    Torque: 106 lb.in (12 Nm)

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18. Install the cowl panel. Refer to: Cowl Panel .
19. Connect the battery negative cable. Refer to: Battery Disconnect and Connect .
20. Pressurize the fuel system. Refer to: Fuel System Pressure Release .