Special Tools

EN-48896 HP Fuel Pump Installation Alignment Gage

1. Install the fuel rail with injectors into the cylinder head evenly.
2. Hand tighten the 2 outer fuel rail bolts to seat the injector into the injector bores.

Notice: Refer to Fastener Notice in the Preface section.

3. Start and hand tighten the remaining fuel rail bolts.

Tighten

•	Tighten the fuel rail bolts in sequence to 22 N·m (16 lb ft).

•	Tighten the fuel rail bolts in sequence a second time to 22 N·m (16 lb ft).




4. Install the fuel injector noise insulator.
5. Connect the electrical harness to the fuel rail harness connection.




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

6. Use the EN-48896 alignment gage (2) to ensure that the camshaft lobe is in the base circle position. At base circle position, the tool will be flush with the head (1).



7. Lubricate the high pressure fuel pump cylinder head bore with 5W30 engine oil.

Important: Ensure that the high pressure fuel pump roller lifter is oriented properly, the camshaft is at base circle, and the number 1 piston is at top dead center (TDC) on the exhaust stroke. The distance from the mounting flange surface to the camshaft at base circle should be 52 mm (2.05 in).

8. Lubricate the high pressure fuel pump roller lifter with 5W30 engine oil and install into the cylinder head bore.



9. Install a NEW high pressure fuel pump gasket.
10. Install a NEW high pressure fuel pump O-ring.

Important: Ensure the plastic bolt retainers are installed in the high pressure fuel pump mounting holes before installing.

11. Install the high pressure fuel pump.
12. Start and hand-tighten the high pressure fuel pump bolts evenly.

Tighten
Tighten the high pressure fuel pump bolts evenly to 15 N·m (11 lb ft).




13. Install and hand-tighten both ends of the NEW high pressure fuel line.

Tighten
Tighten the high pressure fuel line fitting nuts to 30 N·m (22 lb ft).