Fuel Injection Pump: Installation

• 1.
  
  Release the underbody splash shield. fasteners and remove the underbody splash shield.

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• 2.
  
  If equipped, remove the skid plate bolts and remove the skid plate.

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NOTE: The cam lobe for the fuel injection pump must be at Bottom Dead Center (BDC) for the fuel injection pump installation.
NOTE: Only rotate the crankshaft Clockwise (CW) or damage to the engine may occur.
• 3.
  Using the crankshaft pulley bolt, turn the crankshaft until the fuel injection pump cam lobe is at BDC.

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• 4.
  
  Apply clean engine oil to the fuel injection pump mounting pedestal bore, the camshaft lobe and the fuel injection pump roller tappet. Install the fuel injection pump roller tappet. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-30 Super Premium Motor Oil (Canada) XO-5W30-QSP (US); CXO-5W30-LSP12 (Canada); or equivalent.

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• 5.
  
  Inspect the fuel injection pump mounting plate seal and replace as necessary. Lubricate the fuel injection pump mounting plate seal with clean engine oil. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-30 Super Premium Motor Oil (Canada) XO-5W30-QSP (US); CXO-5W30-LSP12 (Canada); or equivalent.

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• 6.
  
  Install a new fuel injection pump O-ring seal. Lubricate the new fuel injection pump mounting plate seal with clean engine oil. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-30 Super Premium Motor Oil (Canada) XO-5W30-QSP (US); CXO-5W30-LSP12 (Canada); or equivalent.

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• 7.
  
  Inspect the fuel injection pump mounting plate O-ring seals and replace as necessary. Lubricate the fuel injection pump mounting plate O-ring seals with clean engine oil. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-30 Super Premium Motor Oil (Canada) XO-5W30-QSP (US); CXO-5W30-LSP12 (Canada); or equivalent.

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NOTE: Make sure that new fuel injection pump bolts are installed.
• 8.
  Install the fuel injection pump mounting plate on to the fuel injection pump. Install the new fuel injection pump bolts.

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• 9.
  
  

  • 1.
    
    Install the fuel injection pump with the fuel injection pump mounting plate, loosely install the new fuel injection pump bolts and loosely install the fuel injection pump plate bolt. Alternately tighten each fuel injection pump bolt one complete revolution until seated. Tighten the 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.

  • 2.
    
    Tighten the fuel injection pump plate bolt to 10 Nm (89 lb-in).

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• 10.
  
  If equipped, install the skid plate and the skid plate bolts.
  • Tighten to 40 Nm (30 lb-ft).

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• 11.
  
  Install the underbody splash shield and the underbody splash shield retainers.

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• 12.
  
  
  NOTE: Apply clean engine oil to the threads of the high-pressure fuel tube flare nut. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-30 Super Premium Motor Oil (Canada) XO-5W30-QSP (US); CXO-5W30-LSP12 (Canada); or equivalent.
  NOTE: Install the high pressure fuel tube flare nut and the new high pressure fuel tube bracket nut finger tight at this stage. Tighten in the stages shown in illustration.
  NOTE: Make sure that a new high pressure fuel tube bracket nut is installed.
  NOTE: Calculate the correct torque wrench setting for the following torque in illustration.

  • 1.
    
    Tighten the high pressure fuel tube to fuel injection pump flare nut in the following 2 stages.
    • Stage 1: Tighten to 15 Nm (133 lb-in).
    • Tighten an additional 45 degrees or 50 Nm (37 lb-ft), whichever comes first.

  • 2.
    
    Tighten the new high pressure fuel tube bracket nut to 10 Nm (89 lb-in).

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• 13.
  
  Connect the fuel injection pump fuel feed tube quick release coupling. Refer to Fuel System - General Information .

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• 14.
  
  Connect the fuel injection pump electrical connector.

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NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.
• 15.
  Install the fuel injection pump noise insulator.

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• 16.
  
  Remove the oil filler cap and install the engine appearance cover. Install the oil filler cap.

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• 17.
  
  Connect the battery ground cable, refer to Battery, Mounting and Cables .

• 18.
  
  Pressurize the fuel system, refer to Fuel System - General Information .