Installation Procedure
- Install the EN-51365 gauge (1).
- Use EN-51365 gauge (1) and rotate the crankshaft until the special tool is flush with the cylinder head. This indicates the camshaft lobe is at base circle position.
- Remove the EN-51365 gauge (1).
- Lubricate the valve lifter follower (1) with engine oil.
- Install the valve lifter follower (1).
- Ensure that the guide pin on the follower is aligned with the groove in the fuel pump bore.
- Install a NEW Fuel Injection Pump Gasket (2)
- Install Fuel Injection Pump (3)
- Install the 2 fuel injection pump bolts (4) alternating in steps of 1/2 turn.
- Tighten Fuel Injection Pump Bolt (4) (Qty: 2) to 25 N.m (18 lb ft)
- Install Fuel Pump Insulator (3) at Fuel Injection Pump (1)
- Connect the electrical connector (2)
- Reposition the engine control module and engine wiring harness bracket (3).
- Install the 2 engine control module and engine wiring harness bracket bolts (2) and tighten to 9 N.m (80 lb in).
- Connect Fuel Feed Front Pipe (1). Refer to: Plastic Collar Quick Connect Fitting Service
- Connect Charge Air Cooler Outlet Air Hose at Throttle Body. Refer to: Charge Air Cooler Outlet Air Tube Replacement
- Install Fuel Feed Intermediate Pipe Replacement
- Connect Battery Negative Cable Disconnection and Connection (with KL9)Battery Negative Cable Disconnection and Connection (without KL9)
- After replacement of the fuel injection pump, use a scan tool to learn functions. Refer to K20 Engine Control Module: Programming and Setup .
NOTE:
The camshaft must be in the base circle position before the high pressure fuel pump is installed.
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.
CAUTION:
Refer to Fastener Caution .