Pump, Fuel Injection, High Pressure: Installation
Observe the following precautions when working on fuel systems: No sparks, open flames or smoking. Avoid inhaling and swallowing fuel. Avoid eye and skin contact with fuel. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing. Failure to observe these precautions may result in fire, explosion, property damage, and serious or fatal injury.
High-pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This could be as high as 207 bar (3, 002 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Inspect for high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system. Fuel under this amount of pressure can penetrate skin causing serious or fatal injury.
The "Fuel Adaptive Parameter Reset" and "Fuel Feed System Component Replacement" scan tool procedures should always be run after a PCM, fuel injector, fuel rail, high pressure pump or fuel pressure sensor is replaced. The procedures should be in the "Miscellaneous Functions" tab in the PCM. Failure to run the procedures may cause DTCs to set in the PCM.
- Lubricate the outside diameter of the roller tappet and the inside diameter of the roller tappet bore in the cylinder head with engine oil.CAUTION:
To avoid side loading damage to the pump during assembly, the nuts need to be run down at the same time, or in alternating one half turn increments. Do not torque to specification until the mounting flange is in full contact with the cylinder head.
- Install the fuel injection pump complete with roller tappet onto the cylinder head and tighten the nuts (1) to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).NOTE:
The side anti-rotation roller must be inserted in the groove on the cylinder head.
- Install the sound protection cover (2) onto the fuel injection pump.
- Install and securely tighten the bolts (2) for the coolant tube.
- Install the NEW high pressure fuel line (2).
- Using the (special tool #2025508140, Wrench, Fuel Line 17mm), tighten the fuel rail fitting and the pressure pump fitting to the proper torque specification. Refer to
TORQUE SPECIFICATIONS .NOTE:
Using an offset torque adapter can affect the actual torque applied to the fittings depending on the length and angle of the adapter relative to the torque wrench.
- Connect the wire harness connector (1) to the fuel injection pump.
- Connect the front fuel supply pipe quick-coupling (3) to the fuel injection pump.
- Install the bolt (1) for the coolant tube and tighten securely.
- Install the Powertrain Control Module (PCM). Refer to MODULE, POWERTRAIN CONTROL (PCM), INSTALLATION .
- Install the catalytic converter. Refer to CONVERTER, CATALYTIC, INSTALLATION .
- Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector.
- Check the high pressure fuel system for leaks. Refer to FUEL SYSTEM/FUEL DELIVERY/DIAGNOSIS AND TESTING .