105. Fuel Pump Installation

Fuel Pump Installation (LLT)

Special Tools

EN 48896 - HP Fuel Pump Installation Alignment Gauge

For equivalent regional tools, refer to Special Tools (Special Tools).





Note: The camshaft must be in the base circle position before the high pressure fuel pump is installed.

1. Use the EN 48896 - alignment gauge (2) to ensure that the camshaft lobe is in the base circle position. At base circle position, the tool will be flush with the head (1).




2. Lubricate the high pressure fuel pump cylinder head bore with 5W30 engine oil.

Note: Ensure that the high pressure fuel pump roller lifter is oriented properly, the camshaft is at base circle and the number 1 piston is at top dead center (TDC) on the exhaust stroke. The distance from the mounting flange surface to the camshaft at base circle should be 52 mm (2.05 in).

3. Lubricate the high pressure fuel pump roller lifter with 5W30 engine oil and install into the cylinder head bore.
4. Install a NEW high pressure fuel pressure fuel pump gasket (4).
5. Install a NEW high pressure fuel pump O-ring (5).

Note: Ensure the plastic bolt retainers are installed in the high pressure fuel pump mounting holes before installing.

6. Install the valve lifter follower (3).
7. Install the high pressure fuel pump (2).

Caution: Refer to Fastener Caution (Fastener Caution).

Caution: Alternately hand-tighten the fuel pump bolts one turn at a time until the pump is fully seated. Trying to draw down the pump without even side-to-side tightening may result in pump plunger damage.

8. Start and hand-tighten the NEW high pressure fuel pump bolts (1) evenly and tighten the high pressure fuel pump bolts to 15 Nm (11 lb ft).




9. Install and hand-tighten both ends of the NEW high pressure fuel line and tighten the high pressure fuel line fitting nuts to 30 Nm (22 lb ft).




10. Install the LH to RH fuel rail crossover pipe and tighten the fuel rail crossover pipe fittings to 30 Nm (22 lb ft).




11. Install the fuel feed pipe (2).
12. Install the fuel feed pipe bolts (1) and tighten to 10 Nm (89 lb in).
13. Install the fuel rail wiring connectors to the fuel feed pipe bracket.




14. Install the fuel rail noise shield (1).