Fuel Injection Pump - High Pressure, Body On
Special Tool(s)
Material
Glow Plug Module Heat Shield:
High-Pressure Fuel Injection Pump Heat Shield:
Fuel Rail Supply Tubes:
High-Pressure Fuel Injection Pump Supply And Return Tubes:
High-Pressure Fuel Injection Pump Cover:
High-Pressure Fuel Injection Pump:
Removal
NOTE: It is recommended that this component be serviced with the vehicle body removed. If the body can be removed, refer to Fuel Injection Pump - High Pressure, Body Off.
1. WARNING: Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.
Shut the engine off and wait until the engine is cool or 5 minutes, which ever is longer, to allow the high-pressure fuel system to bleed off and the fuel to cool.
2. Remove the turbocharger. Carry out the Turbocharger - Body On procedure. Turbocharger - Body On
3. Remove the EGR-oxidation catalytic converter (OC) pipe from the vehicle.
4. Remove the bolt and the retaining nuts for the high-pressure fuel injection pump heat shield. Remove the fuel tube bracket and position aside the ground wire.
5. Remove the remaining 2 bolts and the high-pressure fuel injection pump heat shield.
6. Remove the RH turbocharger inlet pipe.
- In order to remove the RH turbocharger inlet pipe, roll it to the left side of the vehicle and then remove the RH turbocharger inlet pipe.
7. Remove the 3 pushnuts and the glow plug module heat shield.
- Discard the pushnuts.
8. Remove the 2 fuel rail supply tube bracket bolts.
9. CAUTION: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.
Remove and discard the fuel rail supply tubes.
10. CAUTION: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.
Disconnect the fuel injector return tube fitting from the check valve.
11. Remove the high-pressure fuel injection pump supply tube bracket nuts.
12. CAUTION: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.
NOTE: Use a back-up wrench to prevent the fittings in the high-pressure fuel pump from turning. It will be necessary to use a thin or low profile wrench to hold the fittings on the high pressure fuel injection pump.
Remove the nuts and the copper sealing washers for the high-pressure fuel injection pump. Remove the high-pressure fuel injection pump supply tube and fuel injection pump-to-cooler return tube.
- Discard the copper sealing washers.
13. Disconnect the high-pressure fuel injection pump electrical connector.
14. Remove the 5 bolts and the high-pressure fuel injection pump cover.
15. Remove and discard the press-in-place gasket from the high-pressure pump cover.
16. NOTE: Use a thin gasket scraper to separate the gasket from the crankcase.
Disconnect the pressure control valve and volume control valve electrical connectors. Remove the high-pressure fuel injection pump cover gasket.
17. Using the special tool, Dial Indicator Gauge with Holding Fixture, check the high-pressure fuel injection pump drive gear backlash.
Specification: 0.13-0.33 mm (0.005-0.013 in)
18. Remove the bolts and the high-pressure fuel injection pump.
19. NOTE: The high-pressure fuel injection pump drive gear bolt is a LH thread.
If a new pump is being installed, remove the bolt, washer and the high-pressure fuel injection pump gear.
Installation
1. CAUTION: The protruding hub of the high-pressure fuel injection pump drive gear must be facing the high-pressure fuel injection pump. Failure to install the gear correctly will result in engine damage.
NOTE: The high-pressure fuel injection pump drive gear bolt is a LH thread.
If a new pump is being installed, install the high-pressure fuel injection pump drive gear, washer and bolt.
2. Install the high-pressure fuel injection pump and bolts.
- Tighten to 61 Nm (45 lb-ft).
3. NOTE:
- The high-pressure fuel injection pump gear bolt has a LH thread.
- Use a tool such as a Snap-On FRDHM15 torque adapter, or equivalent, to tighten the bolt.
If a new high-pressure fuel injection pump has been installed, tighten the gear bolt.
- Tighten to 77 Nm (57 lb-ft).
4. Using the special tool, check the high-pressure fuel injection pump drive gear backlash.
Specification: 0.13-0.33 mm (0.005-0.013 in)
5. Clean the cover mounting surface and apply a dime-sized bead of sealant at the seams.
6. CAUTION: Inspect the volume control valve and the pressure control valve electrical connectors for damage or obstructions at the connector and mating high-pressure fuel injection pump connector. Verify that the connectors are completely latched to the valve housings or engine damage may occur.
Install a new high-pressure fuel injection pump cover gasket. Connect the pressure control valve and volume control valve electrical connectors.
7. Install a new press-in-place gasket in the high-pressure fuel injection pump cover.
8. NOTE: Do not remove the Fuel System Caps from the high-pressure fuel injection pump until the fuel tubes are being installed.
Install the high-pressure fuel injection pump cover and bolts.
- Tighten to 13 Nm (115 lb-in).
9. Connect the high-pressure fuel injection pump electrical connector.
10. NOTE: If there is metal debris in the high-pressure fuel system, flush the cylinder head fuel passages and the return tubes.
11. NOTE: Use a back-up wrench on the high-pressure fuel injection pump fittings from turning. If the fittings move, the high-pressure fuel injection pump fittings must be retightened.
NOTE: It will be necessary to use a thin or low profile wrench to hold the fittings on the high-pressure fuel injection pump.
Install new sealing washers high-pressure fuel injection pump supply tube fuel injection pump-to-cooler return tube and nuts at the high-pressure fuel injection pump.
^ For Viton� sealing washers tighten to 25 Nm (18 lb-ft).
^ For copper sealing washer tighten to 38 Nm (28 lb-ft).
Install new copper sealing washers, high-pressure fuel injection pump supply tube, fuel injection pump-to-cooler return tube and nuts at the high-pressure fuel injection pump.
- Tighten to 38 Nm (28 lb-ft).
12. Install the 2 high-pressure fuel injection pump supply tube bracket nuts.
- Tighten to 11 Nm (97 lb-in).
NOTE: Use a crowfoot wrench to aid in the tightening the fitting.
13. Connect the fuel injector return tube fitting to the check valve.
- Tighten to 38 Nm (28 lb-ft).
NOTE: Use a back-up wrench to prevent the fittings in the high-pressure fuel injection pump from turning. If the fittings move, the high-pressure fuel injection pump fittings must be retightened. Tighten to 45 N.m (33 lb-ft).
NOTE: It will be necessary to use a thin or low profile wrench to hold the fittings on the high-pressure fuel injection pump.
NOTE: Use a crowfoot wrench to aid in tightening the fuel rail supply tube.
14. Install the new fuel rail supply tubes in the following sequence.
1. Remove the Fuel System Caps from the fuel rail supply tube openings.
2. NOTE: Support the tubes while hand snugging the nut to make sure of correct assembly of the joints.
Position the fuel rail supply tubes between the high-pressure fuel injection pump and the high-pressure fuel rail. Fully hand start and seat the 4 fuel rail supply tube fittings onto the high-pressure fuel injection pump and high-pressure fuel rails.
3 Snug the 4 fuel rail tube fittings.
- Tighten to 2 N.m (18 lb-in).
4 Pre-tighten the 4 fuel rail supply tube fittings.
- Tighten to 12 Nm (106 lb-in).
5 NOTE: Place a visible mark with a permanent marker on the 4 fuel rail supply tube nuts. Turning the fuel injector supply tube nuts one flat of the fitting is equal to 60 degrees.
Final-tighten the fuel rail supply tube fittings.
- Tighten the 4 fuel rail supply tube fittings 60 degrees.
15. Install the 2 fuel rail supply tube bracket bolts.
- Tighten to 13 Nm (115 lb-in).
16. NOTE: Use a socket to aid in installing the retainers.
Install the glow plug module heat shield and pushnuts.
17. Position the RH turbocharger inlet pipe in the vehicle.
18. CAUTION: Failure to correctly install the high-pressure fuel injection pump heat shield may result in engine damage.
Install the high-pressure fuel injection pump heat shield in the vehicle and install the 2 center bolts.
- Tighten to 13 Nm (115 lb-in).
19. Position the fuel tube bracket and ground wire. Install the retaining nuts and bolt for the high-pressure fuel pump shield.
- Tighten the fuel line bracket nuts to 7 Nm (62 lb-in).
- Tighten the remaining fasteners to 13 Nm (115 lb-in).
20. Position the EGR-OC pipe in the vehicle.
21. Install the turbocharger. Carry out the Turbocharger - Body On procedure. Turbocharger - Body On
22. NOTE:Clearing the DTCs or Keep Alive Memory (KAM) does not reset the adaptive values in the POM.
23. NOTE: If the high-pressure fuel injection pump was replaced clear the fuel injector adaptive tables from the PCM using the scan tool. For additional information refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual. Testing and Inspection