High Pressure Pump

REMOVAL
1. Disconnect negative battery cable.
2. Remove viscous fan clutch.
3. Unplug electrical connector at high pressure pump.

CAUTION:
- DO NOT slacken the threaded connection. Use a wrench to counterhold at the threaded connection when loosening and tightening the union nut. DO NOT EXCEED tightening torque.
- DO NOT crimp or bend fuel line. Capture all fluids that flow out of connections.

NOTE: Using a marking pen, make a mark on the outside fuel return line to easily identify proper position during assembly.

4. Unbolt bracket and pressure line at pressure pump.
5. Detach fuel supply and return flow line at high pressure pump.

NOTE: Care must be taken not to drop the high pressure pump driver and intermediate piece if pump is being replaced.

6. Remove bolts attaching high pressure pump and remove pump.

INSTALLATION

CAUTION: Clean sealing surfaces with appropriate solvents and replace all seals.

NOTE: Inspect then attach high pressure pump driver and intermediate piece if pump is being replaced. If wear is present at driver, replace the intermediate gear.

High Pressure Pump:

1. Position and secure the high pressure pump to cylinder head. Tighten bolts to 14 N.m (124 lbs. in.).

CAUTION:
- NEVER slacken the thread connection. Use a wrench to counterhold at threaded connection when slackening and tightening torque in order to avoid also slackening the threaded connection the next time.
- DO NOT crimp or bend fuel line. Inspect sealing cone at line; replace line if compression exists.

NOTE: Care must be taken not to cross the fuel return and supply lines during installation.

2. Attach fuel flow supply and return lines.
3. Install bracket to high pressure pump. Tighten nut to 9 N.m (80 lbs. in.).
4. Attach high pressure fuel line to pump.Tighten to 22 N.m (194 lbs.in.).
5. Install viscous fan clutch.
6. Connect negative battery cable.
7. Refill coolant system with proper mixture to correct level.

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOU HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.

8. Start engine and inspect for leaks.