Fuel Injection Pump

Fuel Injection Pump

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

Material(s)






Exploded View

Intake manifold removed for clarity.










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. 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.
Remove the fuel injection pump noise insulator shield.

2. Release the fuel system pressure. REFER to Fuel System Pressure Release .

3. Disconnect the battery ground cable. REFER to Battery Disconnect .

4. Remove the ACL (Air Cleaner) outlet pipe. REFER to Air Cleaner Outlet Pipe - 2.0L GDI .

5. Disconnect the fuel injection pump electrical connector.

6. Disconnect the fuel jumper tube-to-fuel injection pump quick connect coupling. REFER to Quick Connect Coupling - Type 1 .

7. 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.
Remove the high pressure fuel tube.

1. Remove the high pressure fuel tube bracket bolts.

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

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

4. Remove and discard the high pressure fuel tube.

8. Alternately loosen the 2 fuel injection pump bolts one complete revolution at a time.

1. Remove and discard the 2 fuel injection pump bolts.

2. Remove the fuel injection pump.

3. Remove and discard the fuel injection pump O-ring seal.

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.
Remove the fuel injection pump roller tappet.





1. Inspect the fuel injection pump roller tappet. REFER to Fuel Injection Pump Tappet Inspection .

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

Using the crankshaft pulley bolt, turn the crankshaft clockwise until the fuel injection pump cam lobe is at BDC (Bottom Dead Center).





3. NOTE: Apply clean Motorcraft(R) SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft(R) SAE 5W-20 Super Premium Motor Oil (Canada) to the fuel injection pump roller tappet and to the fuel injection pump cover bore.
Install the fuel injection pump roller tappet.





4. NOTE: Apply clean Motorcraft(R) SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft(R) SAE 5W-20 Super Premium Motor Oil (Canada) to the fuel injection pump O-ring seal.
Install a new fuel injection pump O-ring seal onto the fuel injection pump.

5. 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: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten an additional 45 degrees.

6. Position a new high-pressure fuel tube and hand start the 2 flare nuts in the following order.

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

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

7. Loosely install the high pressure fuel tube bracket bolts.

8. NOTE: Calculate the correct torque wrench setting for the following torque. REFER to Torque Wrench Adapter Formulas .
Tighten the high pressure fuel tube-to-fuel rail flare nut in the following 2 stages.
- Stage 1: Using a torque adapter, tighten to 15 Nm (133 lb-in).
- Stage 2: Tighten an additional 45 degrees.

9. NOTE: Calculate the correct torque wrench setting for the following torque. REFER to Torque Wrench Adapter Formulas .
Tighten the high pressure fuel tube-to-fuel injection pump flare nut in the following 2 stages.
- Stage 1: Using a torque adapter, tighten to 15 Nm (133 lb-in).
- Stage 2: Tighten an additional 45 degrees.

10. Tighten the high-pressure fuel tube bracket bolts.
- Tighten to 10 Nm (89 lb-in).

11. Connect the fuel jumper tube-to-fuel injection pump quick connect coupling. REFER to Quick Connect Coupling - Type 1 .

12. Connect the fuel injection pump electrical connector.

13. Install the ACL (Air Cleaner) outlet pipe. REFER to Air Cleaner Outlet Pipe - 2.0L GDI .

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

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

16. Install the fuel injection pump noise insulator shield.