106. Fuel Pump Installation - RPO LLT

FUEL PUMP INSTALLATION (LLT)

Tools Required: EN-48896 HP Fuel Pump Installation Alignment Gauge






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

1. Use the EN-48896 (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.

Important: 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).

Important: 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).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Notice: 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 high pressure fuel pump bolts (1).

Tighten
Start and hand-tighten the high pressure fuel pump bolts (1) evenly 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.

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.

Tighten
The fuel rail crossover pipe fittings to 30 Nm (22 lb ft).






11. Install the fuel feed pipe.
12. Install the fuel feed pipe bolts.

Tighten
The fuel feed pipe bolts 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.