Fuel Injection Pump

Fuel Injection Pump

Material(s)

Removal

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working on an EVAP (Evaporative Emission) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

NOTICE: Do not loosen any fittings or plugs on the fuel injection pump.

1. Release the fuel system pressure, REFER to Fuel System Pressure Release .

2. Disconnect the battery ground cable, REFER to Battery Disconnect .

3. NOTE: Use care when removing the fuel injection pump noise insulator. Spreading the openings will aid in removing the fuel injection pump noise insulator and reduce the risk of damage.

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4. Remove the ACL (Air Cleaner) outlet pipe, REFER to Intake Air System Components - Exploded View .

5. REFER to Spring Lock Couplings .

6. NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the fuel injection pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of fuel injection pump flare nut.

NOTE: Make sure that a new high pressure fuel tube 9J323 is installed.

8. NOTE: Make sure that new fuel injection pump bolts W500414 are installed.

Alternately loosen the 2 fuel injection pump bolts one complete revolution at a time, remove the 2 fuel injection pump bolts and discard.

1.

9. NOTE: Remove and discard the fuel injection pump O-ring seal 9E583.

Installation

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working on an EVAP (Evaporative Emission) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

NOTICE: Do not loosen any fittings or plugs on the fuel injection pump.

1. NOTE: The cam lobe for the fuel injection pump must be at BDC (Bottom Dead Center) for the fuel injection pump installation.

1. REFER to General Procedure .

3. NOTICE: Only rotate the crankshaft clockwise or damage to the engine may occur.

4. NOTE: Apply clean Motorcraft(R) SAE 5W-30 Premium Synthetic Blend Motor Oil (US); Motorcraft(R) SAE 5W-30 Super Premium Motor Oil (Canada) to the fuel injection pump tappet and to the fuel injection pump cover bore.

5. NOTE: Apply clean Motorcraft(R) SAE 5W-30 Premium Synthetic Blend Motor Oil (US); Motorcraft(R) SAE 5W-30 Super Premium Motor Oil (Canada) to the new fuel injection pump O-ring seal.

NOTE: Make sure that a new fuel injection pump O-ring seal 9E583 is installed.

6. NOTE: Make sure that new fuel injection pump bolts W500414 are installed.
Install the fuel injection pump and loosely install 2 new fuel injection pump bolts, alternately tighten each bolt one complete revolution until seated. Tighten the 2 fuel injection pump bolts in the following 2 stages.
- Stage 1: 5 Nm (44 lb-in)
- Stage 2: 55 degrees.

7.
- 17 Nm (150 lb-in).

9.

1. NOTE: Make sure that a new high pressure fuel tube 9J323 is installed.

2. Hand tighten the high pressure fuel tube-to-fuel rail flare nut.

3. Hand tighten the high pressure fuel tube-to-fuel injection pump flare nut.

10. Loosely install the 2 high pressure fuel tube bracket bolts.

11. NOTE: Calculate the correct torque wrench setting for the following torque. REFER to Torque Wrench Adapter Formulas .
Tighten the 2 high pressure fuel tube flare nuts in the following 2 stages.
- Stage 1: Using a torque adapter, 15 Nm (133 lb-in).
- Stage 2: 30 degrees.

12.
- 10 Nm (89 lb-in).

13. REFER to Spring Lock Couplings .

14. Install the ACL (Air Cleaner) outlet pipe. REFER to Intake Air System Components - Exploded View .

15. NOTE: Use care when installing the fuel injection pump noise insulator. Spreading the openings will aid in installing the fuel injection pump noise insulator and reduce the risk of damage.

16. Connect the battery ground cable. REFER to Battery Disconnect .

17. Pressurize the fuel system. REFER to Fuel System Pressure Release .