Fuel Injection Pump - High Pressure

Fuel Injection Pump - High Pressure









High-Pressure Fuel Injection Pump









Removal

NOTE: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel openings to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.

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.

Release the fuel system pressure. For additional information, refer to Fuel System - General Information - Gasoline and Diesel Fuel System Pressure Release.

2. Remove the fuel rail supply tube. For additional information, refer to Fuel Rail Supply Tube Fuel Rail Supply Tube.

3. Remove the vacuum pump. For additional information, refer to Power Brake Actuation Service and Repair.

4. Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, check the high-pressure fuel injection pump drive gear backlash. For additional information, refer to Specifications.





5. NOTE: The crankshaft gear contains a single timing mark. The camshaft drive gear contains a single timing mark and a double timing mark. The high-pressure fuel injection pump drive gear contains a double timing mark.

The engine is timed correctly when the single mark on the crankshaft drive gear is aligned with the double mark on the camshaft drive gear, and the single mark on the camshaft drive gear is aligned with the double mark on the high-pressure fuel injection pump drive gear. Additionally, the keyway on the high-pressure fuel injection pump drive gear must be in the 12 o'clock position.

NOTE: Engine front cover removed for clarity.

Rotate the crankshaft clockwise, as viewed from the front, until the single mark on the camshaft drive gear and the double mark on the high-pressure fuel injection pump drive gear are aligned.





6. Remove the high-pressure fuel injection pump drive gear nut.

7. Using the Universal Puller or equivalent, remove the high-pressure fuel injection pump drive gear.





8. Remove the 2 fuel rail supply tube bracket bolts and the fuel rail supply tube bracket from the rear of the high-pressure fuel injection pump.

9. Disconnect the volume control valve electrical connector from the top of the high-pressure fuel injection pump.

10. Remove the 3 high-pressure fuel injection pump spacers.

11. NOTICE: Do not pry against the mating surface of the high-pressure fuel injection pump or damage to the high-pressure fuel injection pump may occur.

Slide the high-pressure fuel injection pump off the mounting studs and remove the high-pressure fuel injection pump.

- Remove and discard the high-pressure fuel injection pump mounting O-ring.

Installation

1. Install a new high-pressure fuel injection pump mounting O-ring.

1. Lubricate the high-pressure fuel injection pump mounting O-ring with clean engine oil.

2. Slide the high-pressure fuel injection pump onto the mounting studs, and install the high-pressure fuel injection pump.

2. Install the 3 high-pressure fuel injection pump spacers.
- Tighten to 24 Nm (18 lb-ft).

3. Connect the volume control valve electrical connector at the top of the high-pressure fuel injection pump.

4. Install the fuel rail supply tube bracket and the 2 fuel rail supply tube bracket bolts to the rear of the high-pressure fuel injection pump.
- Tighten to 10 Nm (89 lb-in).

5. NOTE: The crankshaft gear contains a single timing mark. The camshaft drive gear contains a single timing mark and a double timing mark. The high-pressure fuel injection pump drive gear contains a double timing mark.

The engine is timed correctly when the single mark on the crankshaft drive gear is aligned with the double mark on the camshaft drive gear, and the single mark on the camshaft drive gear is aligned with the double mark on the high-pressure fuel injection pump drive gear. Additionally, the keyway on the high-pressure fuel injection pump drive gear must be in the 12 o'clock position.

NOTE: Engine front cover removed for clarity.

Install the high-pressure fuel injection pump drive gear.

- Make sure the single mark on the camshaft drive gear is aligned with the double mark on the high-pressure fuel injection pump drive gear.





6. Install the high-pressure fuel injection pump drive gear nut.
- Tighten to 80 Nm (59 lb-ft).

7. Install the vacuum pump. For additional information, refer to Power Brake Actuation Service and Repair.

8. Install the fuel rail supply tube. For additional information, refer to Fuel Rail Supply Tube Fuel Rail Supply Tube.