- Before continuing, lubricate the cylinder head bore with clean engine oil. Refer to Adhesives, Fluids, Lubricants and Sealers
- Lubricate the valve lifter follower (1) with clean engine oil and install it into the cylinder head bore. Refer to Adhesives, Fluids, Lubricants and Sealers
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- Install the EN-51365
alignment gauge (2) and turn the crankshaft until the camshaft lobe is at the base circle position.
NOTE:
- The camshaft MUST be at the base circle position before the fuel pump is installed.
- At the base circle position, the EN-51365
alignment gauge will sit flush with the cylinder head.
- Remove the EN-51365
alignment gauge (2) and valve lifter follower (1).
- Lubricate the NEW fuel pump housing seal (1) with clean engine oil and install it on the fuel pump. Refer to Adhesives, Fluids, Lubricants and Sealers
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- Install the NEW fuel pump bolts (1) through the fuel pump bolt retainers (2).
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CAUTION:
This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.
NOTE:
- ALWAYS make sure the fuel pump bolt retainers are present before installing the fuel pump bolts.
- If ANY fuel pump bolt retainers are missing or NOT suitable for reuse, replace the retainers as necessary.
- Lubricate the valve lifter follower (1) with clean engine oil and install it into the cylinder head bore. Refer to Adhesives, Fluids, Lubricants and Sealers
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- Install the fuel pump assembly (2) into the cylinder head and start the fuel pump bolts (3) by hand.
- Tighten the NEW fuel pump bolts (3) to 25 N.m (18 lb ft).
CAUTION:
Alternately hand-tighten the fuel pump bolts one turn at a time until the pump is fully seated. Trying to draw down the pump without even side-to-side tightening may result in pump plunger damage.
- Install the fuel pump insulator (1).
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- Position the engine wiring harness bracket (3).
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- Install the engine wiring harness bracket bolts (2) and tighten to 9 N.m (80 lb in).
- Connect the engine wiring harness electrical connectors (1).
- Install the NEW fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement
NOTE:
High pressure fuel feed pipes are one time use only. ALWAYS install a NEW high pressure fuel feed pipe if the pipe is removed OR the fittings are loosened.
- Connect the fuel feed front pipe to the fuel pump. Refer to Fuel Feed Front Pipe Replacement
- Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (without KL9)Battery Negative Cable Disconnection and Connection (with KL9)
- Inspect for leaks using the following procedure:
- Turn ON the ignition with the engine OFF for 2 seconds.
- Turn OFF the ignition for 10 seconds.
- Turn ON the ignition with the engine OFF.
- Inspect for fuel leaks.
- Install the charge air cooler outlet air tube to the throttle body. Refer to Charge Air Cooler Outlet Air Tube Replacement
- Intake Manifold Cover - Install Intake Manifold Cover Replacement
- Use a scan tool to perform any necessary learn procedures. Refer to K20 Engine Control Module: Programming and Setup