Pump-High Pressure Fuel: Installation

WARNING: High pressure fuel lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 1600 bar (23,200 psi). use extreme caution when inspecting for high pressure fuel leaks. Fuel under this amount of pressure can penetrate skin causing personal injury or death. Inspect for high pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.

Fig 1: High Pressure Pump Removal/Installation

Courtesy of DAIMLERCHRYSLER CORP.

1. Install high pressure pump to the left cylinder head. Torque mounting bolts to 14 N.m (10 ft. lbs.).
2. Connect the pump electrical connectors.
3. Install fuel lines at pump.
   Fig 2: Fuel Line Pliers

   Courtesy of DAIMLERCHRYSLER CORP.
4. Install inlet supply line clamp using Fuel Line Pliers 9539.
5. Install return line clamp using Fuel Line Pliers 9539.
   CAUTION: Do not crimp or bend fuel line. Inspect sealing cone at line; replace line if compression exists.
6. Install high pressure fuel line retaining nuts. Torque nuts to 33 N.m (24 ft.lbs.).
7. Install high pressure line support bracket.
8. Install negative battery cable.
9. Install the engine cover.
10. Start engine and check for leaks.