Installation Procedure

NOTE: The camshaft must be in the base circle position before the high pressure fuel pump is installed.

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.
Lubricate the high pressure fuel pump cylinder head bore and roller lifter with camshaft prelube. Refer to ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS .
NOTE: The high pressure fuel pump gasket has a retaining feature to hold the pump retaining bolts in place.

Install the high pressure fuel pump roller lifter (5).

Fig 1: Identifying Fuel Pump Related Components
Courtesy of SAAB-SCANIA OF AMERICA, INC.
Install a NEW high pressure fuel pump O-ring (3).
Position the NEW high pressure fuel pump gasket (4) and bolts (1) to the fuel pump.
Install the high pressure fuel pump (2). Force will be required while hand tightening the bolts.
Refer to CAUTION: RETAINER
Tighten the high-pressure fuel pump's attaching bolts with 15 Nm (11 lb ft) .
Ensure the high pressure fuel pump and fuel rail fittings are clean prior to assembly.
Install a NEW high pressure fuel pipe. Refer to Fuel Feed Intermediate Pipe
Install the fuel feed pipe to the high pressure fuel pump.
Connect the high pressure fuel pump wiring harness.
Install the fuel tank cap.
NOTE: If a fuel leak accrues at the fuel rail, the fuel rail will need to be replaced.

Inspect for leaks using the following procedure:
1. 13.1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. 13.2. Turn OFF the ignition, for 10 seconds.
3. 13.3. Turn ON the ignition, with the engine OFF.
4. 13.4. Inspect for fuel leaks.
Install the pressure relief cap to the fuel feed pipe.
Install the intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT .
Install the high pressure fuel pump shield. Refer to FUEL PIPE SHIELD REPLACEMENT .