Fuel Pump Replacement

Fuel Pump Replacement

Special Tools

EN-48896 - High Pressure Fuel Pump Installation Alignment Gauge

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

Removal Procedure

1. Relieve the low and high side fuel system pressure. Refer to Fuel Pressure Relief Service and Repair.
2. Remove the high pressure fuel pump shield. Refer to Fuel Pipe Shield Replacement Fuel Pipe Shield Replacement.




3. Disconnect the engine wiring harness electrical connector from the high pressure fuel pump.
4. Remove the low pressure feed pipe. Refer to Fuel Feed Pipe Replacement Fuel Feed Pipe Replacement.
5. Remove the high pressure pipe. Discard the pipe. Refer to Fuel Feed Intermediate Pipe Replacement Fuel Feed Intermediate Pipe Replacement.
6. Remove and discard the high pressure fuel pump bolts (1).
7. Remove the high pressure fuel pump (2).
8. Remove and discard the high pressure fuel pump O-ring (3).
9. Remove and discard the high pressure fuel pump gasket (4).
10. Remove the high pressure fuel pump roller lifter (5).

Installation Procedure

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 to ensure that the camshaft lobe is in the base circle position. At base circle the tool will be flush with the head.
2. Lubricate the high pressure fuel pump cylinder head bore and roller lifter with camshaft prelube. Refer to Adhesives, Fluids, Lubricants, and Sealers [1][2]Computers and Control Systems.





Note: The high pressure fuel pump gasket has a retaining feature to hold the pump retaining bolts in place.

3. Install the high pressure fuel pump roller lifter (5).
4. Install a NEW high pressure fuel pump O-ring (3).
5. Position the NEW high pressure fuel pump gasket (4) and bolts (1) to the fuel pump.
6. Install the high pressure fuel pump (2). Force will be required while hand tightening the bolts.

Caution: Refer to Fastener Caution Fastener Caution.

7. Tighten the high pressure fuel pump retaining bolts to 15 Nm (11 lb ft).
8. Ensure the high pressure fuel pump and fuel rail fittings are clean prior to assembly.
9. Install a NEW high pressure fuel pipe. Refer to Fuel Feed Intermediate Pipe Replacement Fuel Feed Intermediate Pipe Replacement.
10. Install the fuel feed pipe to the high pressure fuel pump. Refer to Fuel Feed Pipe Replacement Fuel Feed Pipe Replacement.
11. Connect the high pressure fuel pump wiring harness.
12. Install the fuel tank cap.

Note: If a fuel leak accrues at the fuel rail, the fuel rail will need to be replaced.

13. Inspect for leaks using the following procedure:

1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. Turn OFF the ignition, for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.

14. Install the pressure relief cap to the fuel feed pipe.
15. Install the intake manifold. Refer to Intake Manifold Replacement Intake Manifold Replacement.
16. Install the high pressure fuel pump shield. Refer to Fuel Pipe Shield Replacement Fuel Pipe Shield Replacement.