DD 15 – Section 35.1 High Pressure Fuel Pump

Section 35.1
High Pressure Fuel Pump

The fuel high pressure pump is located at the rear on the left side of the cylinder block and is driven by the pinion gear drive. The high pressure pump supplies the fuel high pressure circuit with fuel and ensures that the fuel required for combustion is available in sufficient quantity and at the required pressure at the fuel injectors, under all conditions.‪

Section 35.1.1
Removal of High Pressure Fuel Pump

Remove as follows:‪

1. Disconnect the batteries.
2. Drain the coolant system.
3. Install engine barring tool to the flywheel housing.
4. Rotate flywheel until the dot that is located inside tooth is aligned with the edge of pointer.
   

   1. Edge of Pointer‪	3. Barring Tool Location‪
   2. Dot Located inside of Tooth‪
5. Remove coolant line from the module to air compressor.
6. Disconnect fuel supply line to the doser block assembly.
7. Disconnect the needle return line.
8. Disconnect amplifier return line.
9. Disconnect fuel lines from the fuel filter module on the manifold at the high pressure pump.
10. Remove fuel filter module.

    PERSONAL INJURY ‪
    To prevent the escape of high pressure fuel that can penetrate skin, ensure the engine has been shut down for a minimum of 10 minutes before servicing any component within the high pressure circuit. Residual high fuel pressure may be present within the circuit.‪

11. Remove two high pressure lines from the high pressure fuel pump to the fuel rail.
12. Remove upper and lower fuel manifolds from the high pressure fuel pump and discard the gaskets.
13. Disconnect electrical connector for the quantity control valve.
14. Remove two bolts securing the high pressure fuel pump bracket to engine block.
15. Remove two nuts securing high pressure fuel pump to bracket.
16. Remove four bolts securing high pressure fuel pump to cylinder block.
17. Remove high pressure fuel pump.

Section 35.1.2
Installation of High Pressure Pump

Install as follows:‪

1. Ensure flywheel is positioned at top dead center (TDC) on cylinder number one.
2. Inspect the high pressure pump:
   1. If driven gear has been installed from the factory, go to step 11 .
   2. If driven gear has been exchanged from the old pump or is installed new, go to step 3 .
3. Install a new high pressure pump into holding fixture W470589014000. Remove locking tooth from the tool.
4. Install key way onto shaft using a brass hammer.
5. Install driven gear onto shaft.
6. Prior to installing the nut mark the gear with paint to show the location of the key way.
   

   1. Paint Mark for Key Way‪
7. Install the nut and locking tooth for tool W470589014000 and using tool J–48669 torque to 250 N·m (184 ft·lb).
8. Position eyebrow plate over gear and align the hash mark on the plate to the paint mark on the gear.
   

   1. Hash Mark Aligned with Key Way‪
9. Install three eyebrow mounting bolts and torque to 30 N·m (22 ft·lb).
10. If not installed; install the high pressure pump into holding fixture W470589014000. Remove the locking tooth from the tool.
11. Use a non marring strap wrench rotate the gear until the hash mark is at the twelve O'clock position.
    

    1. Hash Mark at the twelve O'clock Position‪
12. Remove strap from pump.
13. Install the high pressure pump and new O-ring.

    Note: The pump should slide into the flywheel housing without binding. The bolt hole on the pump housing should align very close with the mounting hole on the flywheel housing.

    

    1. Proper Alignment of the High Pressure Pump to the Flywheel Housing‪

    Note: If the high pressure pump binds when being installed or if there is misalignment in the bolt holes, remove pump and verify timing mark at the twelve O'clock position and reinstall.

    

    NOTICE: ‪

    Ensure the correct bolt length is used when the high pressure pump is installed. If an incorrect bolt length (to long) is used the cup plugs installed in the cylinder block can be pushed out into the gear train causing severe damage to the gear train. The correct bolt length is 35 mm (1.37 in.).‪

14. Install four bolts securing the high pressure pump to the flywheel housing and torque to 60 N·m (44 ft·lb).
15. Install two nuts securing the high pressure fuel pump to bracket and torque to 30 N·m (22 ft·lb).
16. Install two bolts securing high pressure fuel pump bracket to block and torque to 100 N·m (74 ft·lb).
17. Install a new gasket and torque upper fuel manifold bolts of the high pressure fuel pump to 30 N·m (22 ft·lb).
18. Install a new gasket and torque lower fuel manifold bolts of the high pressure fuel pump to 30 N·m (22 ft·lb).
19. Connect quantity control valve connector.
20. Install the fuel lines on fuel filter module.
21. Torque the emergency lubrication line to 35 N·m (26 ft·lb).
22. Torque the fuel inlet for high pressure pump to 45 N·m (33 ft·lb).
23. Torque the fuel return for the high pressure pump to 45 N·m (33 ft·lb).
24. Torque the fuel inlet for the low pressure pump to 45 N·m (33 ft·lb).
25. Torque the fuel return for the low pressure pump to 45 N·m (33 ft·lb).
26. Install the banjo bolts. (Only version four).
27. Torque the amplifier return fitting at the fuel inlet for low pressure pump to 35 N·m (26 ft·lb).
28. Torque the needle return fitting at fuel inlet for high pressure pump to 35 N·m (26 ft·lb).
29. Torque the fuel supply line to doser block assembly 40 N·m (30 ft·lb).
30. Install two high pressure lines from the high pressure pump to the fuel rail and torque fittings to 40 N·m (30 ft·lb).
31. Install fuel filter module.
32. Install coolant line for air compressor.
33. Fill coolant system.
34. Prime system using fuel priming valve or hand primer. Refer to "6.5 Fuel System Priming" , “Fuel System Priming.”

    ENGINE EXHAUST ‪
    To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic.‪

35. Start and run the engine.
36. When the engine has reached operating temperature 140° F (60° C). Observe pump for any performance problems or leaks.