Left-Hand Fuel Rail High-Pressure Fuel Pump

Left-Hand Fuel Rail High-Pressure Fuel Pump
This is a "Trustmark Authoring Standards (TAS) Repair Procedure"
- TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.
- TAS removal and installation procedures use a sequence of color illustrations to indicate the order to be followed when removing/disassembling or installing/assembling a component.
- Many of the TAS procedures will have the installation information within the removal steps.
- The TAS color illustrations use a variety of symbols to indicate important details of the procedures. It is important to understand these symbols in order to properly used the TAS procedures.
Refer to How to Use TAS Procedures and TAS Symbol Glossary at Vehicle | Description and Operation for additional information on these TAS procedures.
For additional information, refer to How to Use TAS Procedures How to Use TAS Procedures

Removal

CAUTION: Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

NOTE:
Removal steps in this procedure may contain installation details.

NOTE:
Some variation in the illustrations may occur, but the essential information is always correct.

All vehicles
For additional information, refer to Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions
For additional information, refer to Fuel System Pressure Release - 5.0L Service and Repair
1 Disconnect the battery ground cable.
For additional information, refer to Specifications Battery and Charging System
For additional information, refer to Engine Oil Draining and Filling Engine Oil Draining and Filling
For additional information, refer to Fuel Injection Component Cleaning Fuel Injection Component Cleaning
For additional information, refer to Air Cleaner Outlet Pipe T-Connector Air Cleaner Outlet Pipe T-Connector

CAUTION: Be prepared to collect escaping fluids.

CAUTION: Be prepared to collect escaping fluids.

CAUTION: Make sure that all openings are sealed. Use new blanking caps.

CAUTION: Be prepared to collect escaping fluids.

CAUTION: Make sure that all openings are sealed. Use new blanking caps.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
2 Raise and support the vehicle.
For additional information, refer to Engine Mount RH Engine Mount RH
For additional information, refer to Generator - Vehicles Without: Supercharger Service and Repair

Left-hand drive vehicles

All vehicles

NOTE:
Engine shown removed for clarity.

CAUTION: Be prepared to collect escaping fluids.

CAUTION: Make sure that all openings are sealed. Use new blanking caps.

NOTE:
Engine shown removed for clarity.

CAUTION: Be prepared to collect escaping fluids.

CAUTION: Make sure that all openings are sealed. Use new blanking caps.

CAUTION: Be prepared to collect escaping fluids.
3 Loosen the Torx screws a turn each at a time.

CAUTION: Be prepared to collect escaping fluids.

Installation
All vehicles

NOTE:
Lubricate the fuel rail high-pressure fuel pump bucket with clean engine oil.

CAUTION: Tighten the Torx screws a turn at a time until the correct torque is achieved.

NOTE:
Lubricate the fuel rail high-pressure fuel pump O-ring seal with clean engine oil.

Torque to: 11 Nm

1 Loosen the Torx screws half a turn each.

CAUTION: Install new high-pressure fuel supply lines.

CAUTION: Lubricate only the union threads with clean engine oil.

NOTE:
Remove and discard the blanking caps.

NOTE:
Engine shown removed for clarity.

NOTE:
Install the bolt and unions fully finger tight before final tightening.

CAUTION: Care must be taken when positioning the fuel rail high-pressure fuel pump cover to one side.

NOTE:
Fuel rail high-pressure fuel pump cover shown removed for clarity.

Torque to: 11 Nm
2 Lower the vehicle.

NOTE:
Do not tighten at this stage.

NOTE:
Remove and discard the blanking caps.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
3 Raise and support the vehicle.

NOTE:
Engine shown removed for clarity.
Unions (1): 21 Nm
M6 (2): 11 Nm
M8 (3): 25 Nm
M5 nut (4): 6 Nm

NOTE:
Engine shown removed for clarity.

Torque to: 21 Nm

NOTE:
Install the bolt and unions finger tight before final tightening.

NOTE:
Remove and discard the blanking caps.
Unions: 21 Nm
M6: 11 Nm

Torque to: 21 Nm

NOTE:
Engine shown removed for clarity.

Torque to: 25 Nm

Left-hand drive vehicles

Torque to: 24 Nm

Torque to: 100 Nm

All vehicles
For additional information, refer to Generator - Vehicles Without: Supercharger Service and Repair
For additional information, refer to Engine Mount RH Engine Mount RH
4 Lower the vehicle.

NOTE:
Do not tighten at this stage.

NOTE:
Remove and discard the blanking caps.

Unions: 21 Nm
Bolts: 8 Nm

Torque to: 21 Nm

For additional information, refer to Air Cleaner Outlet Pipe T-Connector Air Cleaner Outlet Pipe T-Connector
For additional information, refer to Engine Oil Draining and Filling Engine Oil Draining and Filling
For additional information, refer to Specifications Battery and Charging System