High Pressure Fuel Pump Removal and Installation

Flammable - Keep Fire Away

NOTE: Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line.


NOTE:
Do not disconnect the water bypass hoses.
Do not bend the water bypass hoses excessively.

4. Intake Manifold Bracket - Remove

6. High Pressure Fuel Pump Cover - Remove

2.
Remove the high pressure fuel pump cover (B).

7. Fuel Joint Pipe - Remove
1.
Remove the fuel joint pipe (A).

8. High Pressure Fuel Pump - Remove
1.
Disconnect the connector (A).
2.
Loosen the bolts (B) alternately, and remove the high pressure fuel pump (C) with the O-ring (D), and the roller (E).
3.
Remove the fuel feed pipe (A) with the sealing washers (B) from the high pressure fuel pump (C).

9. High Pressure Fuel Pump Cam - Check
1.
Rotate the crankshaft and check the high pressure fuel pump cam (A) for pits, scores, or excessive wear. If needed, replace the intake camshaft.
2.
Set the No. 1 piston at bottom dead center (BDC).
3.
Install the roller (A) to the high pressure fuel pump cam.
4.
Set the gauge (B) on the roller and hold it, then set the dial to zero.
5.
Rotate the crankshaft 720 ° and measure the four cam lobes height. If the cam lobes are excessive worn, replace the intake camshaft.
NOTE: The high pressure fuel pump cam has four cam lobes.
Cam Lobe Height Standard (New): 0.146 in (3.7 mm)


Flammable - Keep Fire Away

NOTE:

1. Camshaft Timing - Set
1.
Check the position of the cam (A) that drives high pressure fuel pump as shown.

2. High Pressure Fuel Pump - Install
1.
Install the fuel feed pipe (A) to the high pressure fuel pump (B) with new sealing washers (C).





2.
Coat the roller (A) and the cam (B) with clean engine oil.

3.
Install the roller (C) and the high pressure fuel pump (D) with a new O-ring (E) coated with clean engine oil. Install the bolts (F) loosely by hand in an alternating pattern.
4.
Connect the connector (G).

3. Fuel Joint Pipe - Install
NOTE: Before you install the fuel joint pipe (A), loosen the high pressure fuel pump mounting bolts (B).
1.
Lubricate the top of the new fuel joint pipe (C) and the threaded area (D) of the fuel rail and the high pressure fuel pump with polyethylene glycol of a new fuel joint pipe kit.
NOTE: Do not reuse the fuel joint pipe.
2.
Tighten the fuel joint pipe nuts (E) by hand until the end of the joint pipe is seated on the fuel rail or high pressure fuel pump.
3.
Set the fuel joint pipe bracket (F) to the cylinder head, and loosely install the bolt (G).
4.
Tighten the high pressure fuel pump mounting bolts (A) to the specified torque.
5.
Tighten the fuel joint pipe bracket mounting bolt (B) to the specified torque.
6.
Tighten the fuel joint pipe nut (C) to the specified torque in the numbered sequence shown.
NOTE: A crowfoot-type special tool increases the torque applied by the torque wrench. Refer to Service Precautions for details on how to recalculate the torque wrench setting.

4. High Pressure Fuel Pump Cover - Install
1.
Install the high pressure fuel pump cover (A).
NOTE: The high pressure fuel pump cover will be reinstalled after the fuel leak check.