High Pressure Pump

High Pressure Fuel Pump:

REMOVAL - HIGH PRESSURE PUMP
(Refer to FUEL SYSTEM - WARNING)

1. Disconnect negative battery cable.
2. Remove viscous fan clutch (Refer to COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL).
3. Unplug electrical connectors at high pressure pump.

CAUTION: DO NOT slacken the threaded connection. Use a wrench to counterhold at the threaded connection when loosening and tightening the union nut. DO NOT EXCEED tightening torque.

CAUTION: DO NOT crimp or bend fuel line. Capture all fluids that flow out of connections.


4. Disconnect the high pressure line at high pressure pump
5. Detach fuel supply and return flow line at high pressure pump using special tool #9539.

NOTE: Care must be taken not to drop the high pressure pump drive when removing pump. Inspect the pump drive for wear. If wear is present replace the drive and gear.

6. Remove bolts attaching high pressure pump and remove pump.

INSTALLATION - HIGH PRESSURE PUMP
(Refer to FUEL SYSTEM - WARNING)

CAUTION: Clean sealing surfaces with appropriate solvents and replace all seals.

NOTE: Inspect then attach high pressure pump drive if pump is being replaced. If wear is present at drive, replace drive and gear.

1. Position and secure the high pressure pump to cylinder head. Tighten bolts to 14 Nm (124 lbs. in.).

CAUTION: NEVER slacken the thread connection. Use a wrench to counterhold at threaded connection when slackening and tightening torque in order to avoid also slackening the threaded connection the next time.

CAUTION: DO NOT crimp or bend fuel line. Inspect sealing cone at line; replace line if compression exists.

NOTE: Care must be taken not to cross the fuel return and supply lines during installation.

2. Attach fuel flow supply and return lines, recrimping clamps using special tool #9539.

CAUTION: NEVER slacken the thread connection. Use a wrench to counterhold at threaded connection when slackening and tightening torque in order to avoid also slackening the threaded connection the next time.

CAUTION: DO NOT crimp or bend fuel line. Inspect sealing cone at line; replace line if compression exists.

3. Attach high pressure fuel line to pump. Tighten to 22Nm (194 lbs.in.).
4. Install the viscous fan.
5. Connect negative battery cable.
6. Start engine, allow to run, turn engine off and inspect for leaks (Refer to FUEL SYSTEM - WARNING), (Refer to FUEL SYSTEM - DIAGNOSIS AND TESTING).